Gek105054 LM2500 Plus O&M Manual

GEK 105054 VOLUME I

ON-SITE OPERATION AND MAINTENANCE MANUAL FOR GE

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

INDUSTRIAL AERODERIVATIVE GAS TURBINES

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

GEK 105054

Highlights of Revision 1, Dated 15 April 2010 CHAPTER

LOCATION

DESCRIPTION OF CHANGE

Chapter 8

Paragraph 8-4.1.5

Updated rpm quantities in step d.

Chapter 10

Paragraph 10-4.5.2

Renumbered paragraph

App-A1

Entire

Updated entire Appendix 1

App-A2

Entire

Updated entire Appendix 2

GEK 105054 VOLUME I



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

COPYRIGHT 2010 General Electric Company, USA


15 APRIL 2009 Change 1 - 15 April 2010

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

GEK 105054 Volume I

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

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

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

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

A

Change No. 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0

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

Change No. 1 0 1 0 0

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

GEK 105054 Volume I


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

Change No. 0 1 1 0 0 0 0

0 0 0 0 0 0 0 0


B/(C Blank)

LM2500+ SAC GE Marine & Industrial Engines

GEK 105054 Volume I

Table of Contents Page Chapter 1

Chapter 2

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

1-1

1-1

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

1-1

1-2

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

1-1

1-3

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

1-1

1-4

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

1-2

1-5

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

1-2

1-6

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

1-2

1-7

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

1-14

1-7.1

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

1-14

1-7.2

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

1-14

1-7.3

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

1-15

1-7.4

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

1-15

1-7.5

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

1-15

1-7.6

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

1-15

1-7.7

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

1-15

1-7.8

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

1-16

1-7.9

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

1-16

1-7.10

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

1-16

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

2-1

2-1

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

2-1

2-2

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

2-1

2-2.1

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

2-1

2-2.2

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

2-1

2-2.3

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

2-2

2-2.4

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

2-3

2-2.5

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

2-3

2-3

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

2-6

2-4

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

2-8

2-4.1

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

2-8

2-4.2

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

2-8


i


GEK 105054 Volume I

Table of Contents - (Cont.) Page Chapter 3

Chapter 4

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

3-1

3-1


3-1

3-2

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

3-1

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

4-1

4-1


4-1

4-2

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

4-1

4-2.1

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

4-1

4-2.2

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

4-2

4-3

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

4-2

4-4

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

4-2

4-4.1


4-2

4-4.2

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

4-14

4-4.3

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

4-17

4-4.4

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

4-18

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

4-21

4-5.1


4-21

4-5.2

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

4-21

4-5.3

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

4-21

4-5.4

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

4-21

4-5.5

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

4-21

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

4-23

4-6.1


4-23

4-6.2

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

4-23

4-6.3

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

4-23

4-6.4

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

4-28

4-6.5

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

4-32

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

4-32

4-7.1

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

4-32

4-7.2

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

4-32

4-7.3

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

4-36

4-7.4

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

4-36

4-7.5

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

4-36

4-7.6

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

4-38

4-7.7

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

4-38

4-5

4-6

4-7

ii



GEK 105054 Volume I

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

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

4-38

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

4-38

4-8.1

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

4-38

4-8.2

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

4-41

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

4-41 4-41

4-8

4-8.3.1

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

4-41

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

4-41 4-41

4-8.5

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

4-44

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

4-44

4-9.1

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

4-44

4-9.2

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

4-44

4-9.3

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

4-44

4-9.4

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

4-44

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

4-44

4-9

4-10

Chapter 5

4-10.1

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

4-44

4-10.2

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

4-46

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

5-1

5-1


5-1

5-2

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

5-1

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

5-1

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

5-3

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

5-3

5-3.1.1

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

5-3

5-3.1.2

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

5-4

5-3.1.3

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

5-4

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

5-4 5-4

5-2.1 5-3 5-3.1

5-4.1

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

5-17

5-4.2

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

5-17

5-4.2.1

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

5-17

5-4.2.2

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

5-17


iii


GEK 105054 Volume I

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

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

5-18

5-5.1


5-18

5-5.2

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

5-18

5-5.3

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

5-18

5-5.4

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

5-18

5-5.4.1

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

5-18

5-5.4.2

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

5-19

5-5.4.3

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

5-19

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

5-19 5-27

5-5.6

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

5-27

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

5-29

5-6.1

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

5-29

5-6.2

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

5-29

5-6.3

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

5-29

5-6.4

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

5-29

5-6.4.1

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

5-29

5-6.4.2

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

5-29

5-6.4.3

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

5-29

5-6.4.4

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

5-6

5-6.4.5

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

5-32 5-32

5-6.6

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

5-32

5-6.7

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

5-32

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

5-33

5-7.1

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

5-33

5-7.2

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

5-33

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

5-33

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

5-33

5-9

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

5-33

5-10

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

5-33

5-7

5-8 5-8.1

iv

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



GEK 105054 Volume I

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

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

5-11.1 5-12 Chapter 6

5-36

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

5-36

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

5-36

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

6-1

6-1


6-1

6-2

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

6-1

6-2.1

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

6-1

6-2.2

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

6-2

6-2.3

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

6-2

6-2.4

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

6-2

6-2.5

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

6-2

6-2.6

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

6-2

6-2.7

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

6-5

6-3

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

6-5

6-4

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

6-5

6-4.1

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

6-5

6-4.2

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

6-5

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

6-7 6-8

6-4.4

6-8

6-5

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

6-11

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

6-11

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

6-11

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

6-11 6-12

6-5.3

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

6-12

6-6

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

6-12

6-7

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

6-13

6-5.1 6-5.1.1


v


GEK 105054 Volume I


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

7-1

7-1


7-1

7-2

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

7-1

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

7-2

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

7-3

7-3.1

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

7-3

7-3.2

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

7-3

7-3.3

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

7-3

7-3.3.1

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

7-3

7-3.3.2

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

7-3

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

7-3 7-3

7-2.1 7-3

7-3.4.1

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

7-4

7-3.4.2

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

7-4 7-5

7-3.4.3

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

7-5

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

7-5 7-5

7-3.4.1.1

7-3.4.5 7-3.4.6

7-18

7-3.5

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

7-3.6

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

7-19

7-3.7

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

7-21

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

7-27

7-4.1

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

7-27

7-4.2

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

7-27

7-4.3

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

7-28

7-4.4

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

7-28

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

7-28

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

7-29 7-30

7-4

7-4.4.1

7-4.5.1 vi

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

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


7-30


GEK 105054 Volume I

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

Chapter 8

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

7-31

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

7-32 7-32

7-4.7

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

7-33

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

7-33 7-34

7-4.9

7-34

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

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

8-1

8-1


8-1

8-2

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

8-1

8-3

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

8-1

8-3.1

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

8-1

8-3.2

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

8-1

8-3.3

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

8-1

8-3.3.1

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

8-2

8-3.3.2

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

8-2

8-3.3.3

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

8-2

8-3.3.4

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

8-2

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

8-3 8-3

8-4.1

Chapter 9

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

8-4

8-4.1.1

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

8-4

8-4.1.2

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

8-4

8-4.1.3

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

8-4

8-4.1.4

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

8-5

8-4.1.5

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

8-5

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

9-1

9-1


9-1

9-2

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

9-1

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

9-1

9-2.1.1

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

9-1

9-2.1.2

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

9-2.2

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

9-2.1


9-2 vii


GEK 105054 Volume I

Table of Contents - (Cont.) Page

Chapter 10

9-2.3

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

9-2

9-2.4

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

9-2

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

10-1

10-1


10-1

10-2

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

10-1

10-3

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

10-1

10-4

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

10-1

10-4.1

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

10-1

10-4.2

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

10-2

10-4.3

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

10-2

10-4.3.1

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

10-7

10-4.3.2

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

10-8

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

10-8 10-10

10-4.5

10-10

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

10-4.5.1

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

10-10

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

10-12 10-12

10-4.6.1

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

10-12

10-4.6.2

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

10-13

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

10-13 10-15

10-4.8

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

10-15

10-4.9

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

10-17

10-4.10

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

10-20

10-4.11

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

10-20

10-4.12

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

10-20

10-4.12.1

viii

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

10-20

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

10-22 10-23

10-4.14

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

10-24

10-4.15

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

10-25

10-4.15.1

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

10-25

10-4.15.2

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

10-28



GEK 105054 Volume I

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

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

10-29

10-4.16.1

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

10-29

10-4.16.2

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

10-30

10-4.16.3

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

10-30

10-4.17

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

10-31

10-4.18 10-4.19

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

10-33 10-33

10-4.20

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

10-33

10-4.21

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

10-34

10-4.21.1

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

10-34

10-4.21.2

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

10-34

10-4.22

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

10-35

10-4.23

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

10-36

10-4.23.1

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

10-36

10-4.23.2

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

10-36

10-4.23.3

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

10-37

10-4.23.4

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

10-37

10-4.24

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

10-42

10-4.25

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

10-42

10-4.25.1

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

10-43 10-44 10-45

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

11-1

11-1


11-1

11-2

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

11-1

11-2.1

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

11-1

11-3

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

11-3

11-4

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

11-3


ix


GEK 105054 Volume I


Appendix A

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

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

12-1 12-1

12-2

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

12-2

12-3

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

12-2

12-4

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

12-2

12-5

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

12-3

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

x


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


GEK 105054 Volume I

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

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

Liquid Fuel Requirements for GE AeroDerivative Gas Turbines A-17

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

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

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

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

A3

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

A4

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

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

xi


GEK 105054 Volume I

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

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

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


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


GEK 105054 Volume I

Table of Contents - (Cont.) Page A6

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

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

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

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


xiii


GEK 105054 Volume I

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

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


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


GEK 105054 Volume I

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

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

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


xv


GEK 105054 Volume I

List of Illustrations - (Cont.) Figure

Page

7-1

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

7-2

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

7-3

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

7-4

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

7-5

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

7-5 7-5

7-11

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

7-5 7-6

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

9-1

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

9-1

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

9-1

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

9-1

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

9-1

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

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


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


GEK 105054 Volume I

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

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

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


xvii


GEK 105054 Volume I

List of Tables Table

Page

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

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

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

7-1

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

7-6

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

7-8

7-3

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

7-10

7-4

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

7-5

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

7-6

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

7-7

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

7-8

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

7-9

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

9-1

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

9-2

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

9-3

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

9-4

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

9-5

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

9-6

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

9-7

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

9-8

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

9-9

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

9-10

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

7-2

xviii



GEK 105054 Volume I

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

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

Change 1

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

xix/(xx Blank)



GEK 105054 Volume I

CHAPTER 1 Introduction 1-1

PURPOSE AND SCOPE OF TECHNICAL MANUAL

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

•

LM2500 PK gas turbine

•

LM2500 GK gas generator

•

LM2500 PV gas turbine

•

LM2500 GV gas generator

1-2

ARRANGEMENT AND USE OF TECHNICAL MANUAL

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

Main topic/paragraph First-level subordinate paragraph

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

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

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

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

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

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION

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

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

CHANGES TO TECHNICAL MANUAL

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

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

GLOSSARY OF TERMS

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

MEASUREMENT UNITS

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



GEK 105054 Volume I

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

GEK 105054 Volume I

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

Abbreviation

Definition

Abbreviation

Definition

abs

Absolute

cm³

Cubic Centimeters

AC

Alternating Current

CRF

Compressor Rear Frame

AGB

Accessory Gearbox

CRFV

Compressor Rear Frame Flange Accelerometer

ALF

Aft Looking Forward

CW

Clockwise

amp

Ampere

DC

Direct Current

Assy

Assembly

Dia

Diameter

b

Bar

Dim

Dimension

b (beta)

Variable Stator Position

DLE

Dry Low Emissions

bhp

Brake Horsepower

-dPS3/dt

Negative Rate of Change of Compressor Discharge Static Pressure

Blisk

Blade/Disc Combination

ECU

Electronic Control Unit

Btu

British Thermal Unit

ELBO

Lean Blow-Out

°C

Degrees Centigrade (Celsius)

EMU

Engine Maintenance Unit

cc

Cubic Centimeter

°F

Degrees Fahrenheit

CCW

Counterclockwise

FIR

Full Indicator Reading

CDP

Compressor Discharge Pressure

FMP

Fuel Manifold Pressure

CFF

Compressor Front Frame

FOD

Foreign Object Damage

CG

Center of Gravity

ft

Foot or Feet

cm

Centimeter

ft²

Square Foot or Feet

cm²

Square Centimeters

FWD

Forward



GEK 105054 Volume I

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

Definition

Abbreviation

Definition

g

Gram

IGHP

Isentropic Gas Horsepower

gal

Gallon

IGKW

Isentropic Gas Kilowatt

GEK

GEAE Publication Identification Number

IGV

Inlet Guide Vane

GG

Gas Generator

in.

Inch

GT

Gas Turbine

in.²

Square Inch

Hg

Mercury

in.³

Cubic Inch

Horiz

Horizontal

IPB

Illustrated Parts Breakdown

hp

Horsepower

J

Joules

HP

High Pressure

kg

Kilogram

HPC

High Pressure Compressor

kcal

Kilocalorie

HPCR

High Pressure Compressor Rotor

kg cm

Kilogram-centimeter

HPCS

High Pressure Compressor Stator

kg m

Kilogram-meter

HPT

High Pressure Turbine

kJ

Kilojoules

HPTR

High Pressure Turbine Rotor

kPa

Kilopascal

hr

Hour

kW

Kilowatt

Hz

Hertz

l

Liter

ID

Inside Diameter

lb

Pound

IGB

Inlet Gearbox

lb/ft²

Pound per Square Foot


GEK 105054 Volume I

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

Abbreviation

Definition

Abbreviation

Definition

l/min

Liters per Minute

OAT

Outside Air Temperature

l/sec

Liters per Second

OD

Outside Diameter

LVDT

Linear-Variable Differential Transformer

OGV

Outlet Guide Vane

m

Meter

oz

Ounce

m³

Cubic Meter

Pa

Pascals

mA

Milliampere

Pamb

Ambient Pressure

Max

Maximum

PCB

Printed Circuit Board

Min

Minimum

PCR

Publications Change Request

mm

Millimeter

PN

Part Number

MW

Megawatt

ppm

Parts per Million

N

Newton

Prcp

High Pressure Recoup Pressure

N•m

Newton-meter

PS3

High Pressure Compressor Discharge Static Pressure

No.

Number

PT

Power Turbine

NGG

Gas Generator Speed

PT5.4 (also referred to as PT48)

Power Turbine Inlet Total Pressure

NOx

Oxides of Nitrogen

P0

Gas Turbine Inlet Pressure

NPT

Power Turbine Speed

P2

Compressor Inlet Total Pressure



GEK 105054 Volume I

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

Definition

Abbreviation

Definition

qt

Quart

Temp

Temperature

rpm

Revolutions per Minute

TGB

Transfer Gearbox

RTD

Resistance Temperature Detector

theta 2

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

SAC

Singular Annular Combustor

TMF

Turbine Mid Frame

sec

Second

TRF

Turbine Rear Frame

SG

Specific Gravity

TRFV

Turbine Rear Frame Flange Accelerometer

shp

Shaft Horsepower

T2

Compressor Inlet Total Temperature

SI

Metric System

T3

Compressor Discharge Temperature

S/O

Shutoff

T5.4 (also referred to as T48)

Power Turbine Inlet Temperature

Standard Atmosphere

atm

UV

Ultra Violet

Surf

Surface

v

Volt

SWP

Subordinate Work Package

vac

Volts, Alternating Current

Tamb

Ambient Temperature

VG

Variable-Geometry

TAN

Total Acid Number

VSV

Variable Stator Vane

TBP

To Be Provided

WP

Work Package

T/C

Thermocouple


GEK 105054 Volume I

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

To Convert From

To

Multiply By

bhp

kW

0.7457142

Btu

Joules (J)

1054.8

Btu/hr

kJ/hr

1.0548

Btu/hr

kcal/hr

0.2520

Btu/kW-hr

Btu/hp-hr

1.341

Btu/kW-hr

kcal/kW-hr

0.25198

Btu/kW-hr

kJ/kW-hr

1.0548

Btu/lb

kcal/kg

0.5555

cm

in.

0.3937

cm

m

0.01

cm

mm

10

cm/sec

ft/sec

0.03281

Degrees Fahrenheit − 32

Degrees Celsius

0.5555

ft²

m²

0.0929

ft³/hr

l/hr

28.32

ft³/hr

m³/hr

0.02832

ft³/min

l/min

28.32

ft³/min

m³/min

0.02832

ft

cm

30.48

ft

m

0.3048

ft lb (lb ft)

kg m

0.1383

ft lb (lb ft)

N•m

1.356

ft lb (lb ft)

Btu

0.001286



GEK 105054 Volume I

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

To

Multiply By

ft lb/min

ft lb/sec

0.016667

ft/min

km/hr

0.018288

ft/sec

cm/sec

30.48

ft/sec

m/sec

0.3048

g

oz

0.03527

g/cm³

lb/in.³

0.03613

gal

l

3.785

gal/min

l/sec

0.06309

in.²

m²

645.16

in.³

cm³

16.387

in.

mm

25.4

in.

m

0.02540

in.

cm

2.540

in. Hg (60°F)

pascal (Pa)

0.3377

in. water (60°F)

pascal (Pa)

248.8

kg

lb

2.2046

kg cm

lb in.

0.867

kg m

lb ft

7.233

kg/m²

lb/ft²

0.2048

km

miles

0.6214

kW

bhp

1.3409961

lb

g

453.59


GEK 105054 Volume I

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

To Convert From

To

Multiply By

lb

kg

0.4536

lb

N

4.4482

lb/ft²

kg/m²

4.8828

lb/gal

kg/l

0.11982

lb in.

kg cm

1.1532

lb in.

N•m

0.1129848

lb/in.²

kg/cm²

0.0703

lb/in.²

Pascals (Pa)

6894.76

lb/in.²

kPa

6.8948

lb/hr

kg/hr

0.4536

m²

ft²

10.76426

m³

in.³

61,023

m

cm

100

m

ft

3.2808

m

in.

3937

microinches

micrometers

0.0254

micrometers

microinches

39.37

mile (statute)

km

1.6093

mm

in.

0.03937

N

lb

0.2248

N•m

lb in.

8.850748

N•m

lb ft

0.73756

oz

g

28.3495



GEK 105054 Volume I

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

To

Multiply By

oz/gal

g/l

7.49

psi

kPa

6.894757

qt

l

0.9463

U.S. horsepower

metric horsepower

1.014

U.S. horsepower

kW

0.7457

Table 1-3. Pressure Conversions Bar (b)

Standard Atmosphere (atm )

Kilograms per square centimeter (kg/cm²)

Pounds per square inch (lb/in.²)

Pascals(Pa)

1.0

0.987

1.020

14.504

100,000

1.013

1.0

1.033

14.696

101,325

0.981

0.968

1.0

14.22

98,067

0.0689

0.068

0.0703

1.0

6,895


GEK 105054 Volume I

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

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



GEK 105054 Volume I

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

Decimal

Fraction

Decimal

Fraction

Decimal

1/64

0.0156

11/32

0.3438

11/16

0.6875

1/32

0.0312

23/64

0.3594

45/64

0.7031

3/64

0.0469

3/8

0.3750

23/32

0.7188

1/16

0.0625

25/64

0.3906

47/64

0.7344

5/64

0.0781

13/32

0.4062

3/4

0.7500

3/32

0.0938

27/64

0.4219

49/64

0.7656

7/64

0.1094

7/16

0.4375

25/32

0.7812

1/8

0.1250

29/64

0.4531

51/64

0.7969

9/64

0.1406

15/32

0.4688

13/16

0.8125

5/32

0.1562

31/64

0.4844

53/64

0.8281

11/64

0.1719

1/2

0.5000

27/32

0.8438

3/16

0.1875

33/64

0.5156

55/64

0.8594

13/64

0.2031

17/32

0.5312

7/8

0.8750

7/32

0.2188

35/64

0.5469

57/64

0.8906

15/64

0.2344

9/16

0.5625

29/32

0.9062

1/4

0.2500

37/64

0.5781

59/64

0.9219

17/64

0.2656

19/32

0.5938

15/16

0.9375

9/32

0.2812

39/64

0.6094

61/64

0.9531

19/64

0.2969

5/8

0.6250

31/32

0.9688

5/16

0.3125

41/64

0.6406

63/64

0.9844

21/64

0.3281

21/32

0.6562

1

1.0000

43/64

0.6719


GEK 105054 Volume I 1-7

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

SAFETY PRECAUTIONS

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

Material Hazards WARNING

•

•

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

1-7.2

Fire Hazards WARNING

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



1-7.3

Compressed Air Hazards WARNING

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

Heated/Chilled Part Hazards WARNING

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

Electrical Hazards WARNING

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

GEK 105054 Volume I

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

Paints and Finishes Hazards WARNING

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

Procedural Hazards WARNING

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


GEK 105054 Volume I


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

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

WARNING

•

Tooling Hazards WARNING

•

•

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

Environmental Hazards

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

1-7.10

Gas Turbine Operational Hazards WARNING

•

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

•

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



•

GEK 105054 Volume I

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

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

WARNING

•

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

•

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

•

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

•

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

•

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

•

THE GAS TURBINE MUST BE SHUT DOWN.


GEK 105054 Volume I

•

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

•

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

•

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

•

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

•

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

•

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

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING

•

EAR PROTECTION MUST BE WORN IF GAS TURBINE IS OPERATING.

•

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

•

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

•

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



GEK 105054 Volume I

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

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

•

Six-stage PT (GT only)

•

Inlet duct and centerbody (except spare engine)

•

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

•

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

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

•

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

•

Specified fuel system (nozzles and manifolds)

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

•

Ignition system (igniter and exciter)

•

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

•

Set of instrumentation sensors

•

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

2-1

PURPOSE AND SCOPE

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

GENERAL DESCRIPTION AND FEATURES

2-2.1

2-2.2 a.

General Description

Standard Equipment and Features

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


GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE

•

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

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

•

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

•

Externally replaceable gearbox bearings and seals.

•

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

b.

c.

d.

e.

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

2-2.3

Standard Instrumentation

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

•

Lube oil supply line (one location)

•

Lube oil scavenge return line (one location)

•

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

•

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

•

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

•

Accessories/instrumentation externally mounted for ease of replacement.

•

Individually replaceable compressor rotor blades.

•

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

•

Individually replaceable compressor stator vanes.

•

Fuel manifold pressures (depending on selected fuel system)

•

Individually replaceable high pressure turbine rotor (HPTR) blades.



GEK 105054 Volume I

Table 2-1. Standard Instrumentation Qty/Engine

Parameter/Sensor Description

2

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

2

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

1

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

2 (1)

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

2

Ultraviolet combustor flame sensors (purchaser must supply when required)

6

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

5

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

1

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

2

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

2

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

2 (1)

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

•

Second ignition system

See Table 2-2.

•

Inlet screen and inlet seal

2-2.5

•

Ultraviolet flame detectors

•

Air/oil separator piping

•

Mounting kit

2-2.4

Standard Supply Requirements

Optional Equipment

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

•

Pneumatic or hydraulic starter

•

Exhaust diffuser


GEK 105054 Volume I

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

Mechanical Interface Connections

Nomenclature

Mates With

F1

Natural Gas Manifold Inlet

Fuel Control Unit

F1A

Gas Manifold Inlet

Fuel Control Unit

F2

Liquid Fuel Manifold Inlet

Fuel Control Unit

F6

Liquid Fuel Manifold Inlet No. 2

Fuel Control Unit

L1

Lube Pump Inlet Port

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

L2

Lube Pump Discharge Port

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

L3

Lube Pump Scavenge Oil Discharge Port

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

L4

Lube Supply Inlet Port

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

A4

Inlet Duct Seal Flange

If Required

A6

Starter Air Inlet Port (Optional)

A7

Starter Air Outlet Port (Optional)

A10

CDP Seal Port Leakage No. 1

If Required

A10A

CDP Seal Port Leakage No. 1 (Alternate)

If Required

A11

CDP Seal Port Leakage No. 2

If Required

A11A

CDP Seal Port Leakage No. 2 (Alternate)

If Required

A12

Air/Oil Separator Discharge Port

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

A26

GG Aspirator Air Supply

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

D3

Lube Manifold Forward Oil Drain

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

D5

Lube Manifold Aft Oil Drain

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

D7

Starter Drain

D8

Lube Pump Maintenance Drain

S1

Water-wash Manifold Inlet Port

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

W1

Fuel Manifold Water Inlet

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



GEK 105054 Volume I

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

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

)

Mates With Flange from Steam Supply to CDP Steam Manifold

Flange from Steam Supply to CDP Steam Manifold

Flange from Steam Supply to CDP Steam Manifold

MS20819-12/MS9197-12

MS20819-12/MS9197-12

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

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




MODEL SUMMARY

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

•

Natural gas/steam injection NOx - 25 ppm

•

Natural gas/water injection NOx - 42 ppm

•

Liquid fuel/water injection NOx - 42 ppm

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

Table 2-3. LM2500+ SAC Configurations

Configuration

Fuel System Type

PT Type

NOx Suppression Method

Gas turbine

Gas fuel

6-stage PT

None

7LM2500-PK-MG

Gas turbine

Dual fuel

6-stage PT

None

7LM2500-PK-MD

Gas turbine

Liquid fuel

6-stage PT

None

7LM2500-PK-ML

Gas turbine

Gas fuel

6-stage PT

Steam

7LM2500-PK-MGS

Gas turbine

Dual fuel

6-stage PT

Water

7LM2500-PK-MDW

Gas turbine

Dual fuel

6-stage PT

Steam

7LM2500-PK-MDS

Gas turbine

Liquid fuel

6-stage PT

Steam

7LM2500-PK-MLS

Gas turbine

Liquid fuel

6-stage PT

Water

7LM2500-PK-MLW

Gas turbine

Gas fuel

6-stage PT

Water

7LM2500-PK-MGW

Gas turbine

Liquid fuel

2-stage PT

None

7LM2500-PV-ML

Gas turbine

Gas fuel

2-stage PT

None

7LM2500-PV-MG

Gas turbine

Dual fuel

2-stage PT

None

7LM2500-PV-MD

Gas turbine

Liquid fuel

2-stage PT

Steam

7LM2500-PV-MLS

Gas turbine

Gas fuel

2-stage PT

Water

7LM2500-PV-MGW

Model Number



GEK 105054 Volume I

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

Configuration

Fuel System Type

PT Type


Gas turbine

Dual fuel

2-stage PT

Water

7LM2500-PV-MDW

Gas turbine

Liquid fuel

2-stage PT

Water

7LM2500-PV-MLW

Gas turbine

Gas fuel

2-stage PT

Steam

7LM2500-PV-MGS

Gas generator

Gas fuel

None

None

7LM2500-GK-MG

Gas generator

Dual fuel

None

None

7LM2500-GK-MD

Gas generator

Liquid fuel

None

None

7LM2500-GK-ML

Gas generator

Gas fuel

None

Steam

7LM2500-GK-MGS

Gas generator

Dual fuel

None

Water

7LM2500-GK-MDW

Gas generator

Liquid fuel

None

Steam

7LM2500-GK-MLS

Gas generator

Liquid fuel

None

Water

7LM2500-GK-MLW

Gas generator

Gas fuel

None

Water

7LM2500-GK-MGW

Gas generator

Dual fuel

None

None

7LM2500-GV-MD

Gas generator

Gas fuel

None

None

7LM2500-GV-MG

Gas generator

Dual fuel

None

Water

7LM2500-GV-MDW

Model Number



HERITAGE OF THE LM2500+ SAC

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

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines e.

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

f.

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

Gas Generator Changes

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

2-4.2

6-Stage Power Turbine Changes (PK Models)

a.

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

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

b.

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

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

c.

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

d.

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

b.

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

c.

d.



GEK 105054 Volume I

CHAPTER 3 Gas Turbine Package 3-1

PURPOSE AND SCOPE

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

PACKAGE DESCRIPTION

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

•

Gas turbine base

•

Mounting structure

•

Sound enclosure

•

Inlet and exhaust systems

•

Controls and electrical systems

•

Drains and vents

•

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

•

Instrumentation and condition-monitoring systems

•

Cooling systems

•

Rear drive interfaces

•

Noise and emission suppression systems

•

Interconnecting wiring and piping

•

Fire and safety systems

•

Starter system

•

Water-wash system

•

Anti-icing sytem, if applicable

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


GEK 105054 Volume I

CHAPTER 4 Gas Turbine Assembly Description 4-1

PURPOSE AND SCOPE

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

GENERAL DESCRIPTION

4-2.1

Main Components

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

•

Compressor front frame (CFF) assembly

•

Seventeen-stage high pressure compressor (HPC)

•

Compressor rear frame (CRF) assembly

•

Combustion section (SAC)

•

High pressure turbine (HPT)

•

Turbine mid frame (TMF)

•

Accessory drive assembly and accessories

•

Bearings

•

Seals

•

Power turbine (PT) (GT only)

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


GEK 105054 Volume I


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

Engine Airflow

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

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

COMPRESSOR FRONT FRAME

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

HIGH PRESSURE COMPRESSOR General Description

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



GEK 105054 Volume I

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



GEK 105054 Volume I

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



GEK 105054 Volume I

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

GEK 105054 Volume I


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


GEK 105054 Volume I

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



GEK 105054 Volume I

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

GEK 105054 Volume I


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


GEK 105054 Volume I

Figure 4-6. Compressor Front Frame Strut Positions


GEK 105054 Volume I 4-4.2

High Pressure Compressor Rotor

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

•

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

•

Stage 1 disk

•

Stage 2 disk with air duct forward interface

•

Stages 3-9 spool

•

Stages 10-13 spool with integral aft shaft

•

Overhung stages 14-16 spool

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



GEK 105054 Volume I

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

GEK 105054 Volume I


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


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

GEK 105054 Volume I

4-4.3

High Pressure Compressor Stator

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

Figure 4-9. Compressor Stator Assembly


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

Compressor Rear Frame

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

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



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

GEK 105054 Volume I


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



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

COMBUSTION SECTION General Description

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

Cowl Assembly

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

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4-5.3

Dome

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

Combustor Liners

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

Igniter/Flame Sensor

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


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Figure 4-11. Combustor Assembly Cross Section



4-6 4-6.1

HIGH PRESSURE TURBINE General Description

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

Stage 1 HPT Nozzle Assembly

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

GEK 105054 Volume I

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

High Pressure Turbine Rotor

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


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

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

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



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

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


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Figure 4-15. HPT Rotor Assembly Cross Section


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

Stage 2 HPT Nozzle Assembly

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

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



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

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


GEK 105054 Volume I

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

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

Turbine Mid Frame Assembly

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

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

ACCESSORY DRIVE COMPONENTS

4-7.1

General

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

Accessory Drive Train

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



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

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


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

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Figure 4-23. Inlet Gearbox 4-7.3

Inlet Gearbox

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

4-7.4

Radial Drive Shaft

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

Transfer Gearbox

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



GEK 105054 Volume I

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



Accessory Gearbox

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

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

Lube and Scavenge Pump

•

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

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

•

Lube and scavenge pump

4-8

•

Hydraulic pump/VSV servovalve

4-8.1

•

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

The AGB provides drive provisions for the following:

4-7.7

Air-Oil Separator

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

POWER TURBINE General NOTE

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



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Figure 4-25. Air-Oil Separator


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


4-8.2

Power Turbine Rotor

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

Blades and Seals

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

Power Turbine Stator

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

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4-8.3.1

Stage 1 Nozzle

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

Shrouds and Seals

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

Turbine Rear Frame

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


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


GEK 105054 Volume I

Figure 4-28. Turbine Rear Frame Cross Section


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

Flexible Coupling Adapter

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

BEARINGS General

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

Power Turbine (6-Stage)

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


•

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

•

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

4-9.4

Mounting

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

SEALS Oil Seals

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



GEK 105054 Volume I

Figure 4-29. Gas Turbine Bearings

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

GEK 105054 Volume I


Figure 4-31. Carbon Oil Seal 4-10.2

Air Seals

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



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Figure 4-32. Labryinth/Honeycomb Air Seal

Figure 4-33. Fishmouth Air Seal



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CHAPTER 5 LM2500+ SAC System Descriptions 5-1

PURPOSE AND SCOPE

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

5-2

VARIABLE-GEOMETRY CONTROL SYSTEM

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

•

Variable-geometry (VG) control system

•

Fuel system

•

Starting system

•

Lube system

•

Sensors and indicating systems

•

Electrical system

•

Bleed air system

•

Balance piston system for power turbine

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

•

High pressure (HP) recoup system

5-2.1

•

Air system tubing and frame strut functions

•

Engine control unit (ECU)

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

Variable Stator Vane System


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Figure 5-1. VG System



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

FUEL SYSTEM

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

GEK 105054 Volume I

5-3.1

General

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

Natural Gas

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


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

Fuel Manifold

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

Fuel Nozzles

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

5-3.1.4

Fuel Control System

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

STARTING SYSTEM

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



GEK 105054 Volume I

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

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


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

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


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


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


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


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


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Figure 5-11. Liquid Fuel Manifold Configuration


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



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Figure 5-13. Dual Fuel Manifold Configuration


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Figure 5-14. Accessory Gearbox Assembly



5-4.1

GE Starter Usage

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

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

•

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

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

Starter Duty Cycles

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

Starting

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

•

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

5-4.2.2

Hydraulic Starter

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

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




LUBE SYSTEM

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

•

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

•

Operate the actuators for the IGV and VSV systems.

•

Maintain a supply of oil to the optional pneumatic starter.

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

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

Oil Specification

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

Lube Subsystems Lube Supply Circuit

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



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

Scavenge Oil Circuit

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

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5-5.4.3

Engine Drains

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

Sump Vent Circuit

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


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



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


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

Fluid

Flow

Pressure

Temperature

Lube Pump Inlet

Oil

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

0 - 1.0 psig (0 - 6.89 kPa gage)

140 to 160°F (60.0 to 71.1°C)

Lube Supply to Filter

Oil

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

15 - 100 psig (103.4 - 689.5 kPa gage)

140 to 160°F (60.0 to 71.1°C)

Engine Lube Supply

Oil

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

15 - 68 psig (103.4 - 468.8 kPa gage)

140 to 160°F (60.0 to 71.1°C)

Scavenge Discharge to Filter

Oil

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

0 - 25 psig (0 - 172.4 kPa gage)

175 to 275°F (79.4 to 134.9°C)

Air

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

0 - 25 psig (0 - 172.4 kPa gage)

175 to 275°F (79.4 to 134.9°C)

Oil

15 cm³/hr max

2 in. H²O max

200°F max (93.3°C)

Air

0.25 lb/sec max (0.113 kg/sec)

36 in. H²O max

350°F max (176.7°C)

Air/Oil Separator Discharge

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

Sump Pressurization

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

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

Oil Consumption

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


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

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


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

Vibration Sensors

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

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5-6.4

Pressure/ Temperature Sensors

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

HPC Discharge Temperature (T3)

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

Exhaust Gas Temperature (T5.4)

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

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

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

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


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Figure 5-18. Speed Pickups.



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

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

Additional Pressure Parameters

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


•

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

•

Line volume limits exist on the PS3 sensors.

5-6.5

Chip Detectors

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

•

Lube oil supply line, one location

•

Lube oil scavenge return line, one location

•

HPC discharge static pressure (PS3), two locations

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

•

HP recoup pressure (Prcp), two locations

5-6.7

•

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

•

Water pressure at fuel manifold inlet, one location

•

PT inlet pressure (PT5.4), one location

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

•

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

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

5-6.6

Variable-Geometry Position

Flame Sensors

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



5-7

ELECTRICAL SYSTEM

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

Ignition System NOTE

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

Cabling

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

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5-8

BLEED AIR SYSTEM

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

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

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

HIGH PRESSURE RECOUP SYSTEM

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


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



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

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

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

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

ENGINE CONTROL UNIT

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



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CHAPTER 6 Service and Support Requirements 6-1

PURPOSE AND SCOPE

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

•

Shipping

•

Storage

•

Installation/removal

•

Auxiliary systems

•

Support services

•

Maintenance

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

SHIPPING

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

NOTE

•

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

•

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

6-2.1

Engine Shipment CAUTION

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

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




Engine Shipping Container

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

Power Turbine Shipment

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

Power Turbine Shipping Container

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

Enclosure Shipping

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

Highway Shipping CAUTION

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

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



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

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


6-2.7

On-Site Transportation CAUTION

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

STORAGE

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

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6-4.1

Installation/Removal Methods

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

•

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

•

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

•

Lubrication system is flushed with rust preventative.

•

Inlet is covered.

6-4.2

•

Exhaust is covered.

•

Lines are connected or capped.

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

•

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

•

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

Size/Weight

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

INSTALLATION/REMOVAL

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

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



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

•

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

•

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

•

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

•

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

•

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

•

Inlet Gearbox: 38 pounds (17.2 kg)

•

Transfer Gearbox: 245 pounds (111.1 kg)

•

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

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

•

Compressor Rotor: 552 pounds (250.4 kg)

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

•

Compressor Stator Casing: 370 pounds (167.8 kg)

•

Compressor Aft Case: 93 pounds (42.2 kg)


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Compressor Rear Frame: 421 pounds (191.1 kg)

•

Combustor: 120 pounds (54.4 kg)

•

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

•

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

•

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

•

Turbine Mid Frame: 580 pounds (263.1 kg)

•

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

•

LP Turbine Stator: 601 pounds (272.6 kg)

•

TRF: 1,071 pounds (485.7 kg)

•

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

6-4.3

Engine Mount Attachments

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

•

The dead weight of the GT/ GG including fuel system

•

The torque reaction imposed by power extraction

•

Engine self-induced vibration and two blade-out loads

•

Exhaust gas loads

•

Flexible coupling loads


•

Output shaft loads

•

Any other induced loading

The GT engine’s mount locations are as follows:

•

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

•

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

•

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

6-4.4

Flange Interfaces

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



GEK 105054 Volume I

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

GEK 105054 Volume I


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


6-5

AUXILIARY SYSTEMS

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

Inlet System

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

GEK 105054 Volume I

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

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

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

•

6-5.1.2

6-5.1.1

•

Air Filtration

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

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

Anti-Icing

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


GEK 105054 Volume I


Figure 6-5 Temperature Limits 6-5.2

Exhaust System

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

Secondary Cooling Air

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

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

SUPPORT SERVICES

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

•

Unloading and installation of all equipment

•

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



•

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

•

Lubrication system external to the engine

•

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

•

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

•

Fire detection and protection system

•

Water supply and control system for waterwashing of the engine

•

Anti-icing system (as applicable)

•

Vent and drain system

•

Electrical power supply

•

Control and instrument panel, including all interconnecting wiring and piping

•

Water or steam supply and control system (if applicable)

•

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

•

Personal safety protection features

•

Condition-monitoring system

GEK 105054 Volume I

6-7

MAINTENANCE

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



GEK 105054 Volume I

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

PURPOSE AND SCOPE

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

7-2

SAFETY

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

•

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

•

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

•

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

•

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

•

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

•

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


GEK 105054 Volume I


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

•

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

•

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

•

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

7-2.1

SECONDARY AIR TO THE ENCLOSURE SHALL BE SHUT OFF

•

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

•

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

•

EAR PROTECTION SHALL BE WORN IF THE ENGINE IS OPERATING

•

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

•

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

Engine Maintenance/ Inspection Precautions WARNING

•

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

•

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

•

•

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

WARNING

•

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



•

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

7-3

INSTALLATION

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

Site Information

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

Installation Procedure NOTE

•

•

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

a.

Install and align engine per packager's instructions.

b.

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

c.

Install ignition leads per WP 103 00.

GEK 105054 Volume I

7-3.3

Equipment Protection

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

Inlet Cover

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

Exhaust Cover

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

Electrical, Fluid, and System Interface Covers

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

Engine Protection

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


GEK 105054 Volume I 7-3.4.1


Lubricating Oil Requirements

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

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

b.

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

c.

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

d.

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

e.

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

f.

Mixing of different types (Type I versus Type II) of oils is not allowed. Mixing of oil brands of the same type is acceptable. Topping off when changing oil brands of the same type is the preferred method, but indiscriminate changing is not recommended.

CAUTION FOLLOWING THIS FLUSHING, THE SYSTEM FILTER ELEMENTS SHOULD BE REMOVED OR REPLACED TO AVOID ENGINE CONTAMINATION. h.

In the event of a failure during site operation that involves the engine lube system, the complete system should be disconnected, drained, and cleaned as described in the preceding step. This procedure should be followed whether the engine is removed and replaced or repaired on-site.

i.

Engine oil should be filtered to 10 microns, nominal.

7-3.4.1.1 Lube Oil Pressure Corrections For Industrial LM2500+ SAC Gas Turbines and Gas Generators Tables 7-1 through 7-4 and Figures 7-1 through 7-4 provide corrections and limits for lube supply pressure. NOTE

•

There can be significant site-to-site variation in typical lube system parameters based on variations in package designs, lube filters, and site engine operating profiles. A significant rise in lube scavenge temperature, or scavenge filter ΔP, can occur without reaching the recommended alarm or shutdown limits. It is possible for substantial secondary damage to occur in the time following a significant increase in scavenge temperature or filter ΔP prior to reaching the alarm/shutdown limits.

•

GE recommends that operators establish baseline readings for:

CAUTION FAILURE TO PROPERLY MAINTAIN A CLEAN LUBE SYSTEM COULD RESULT IN PREMATURE FAILURE OF THE GT OR COMPONENTS. g.

Before the initial motoring and start of an engine in a new installation or following work on the lube system, the lube oil conditioning and storage system and all of the various circuits should be flushed to ensure cleanliness.

1. Lube scavenge temperatures for all engine sumps and the gearbox



2. Lube scavenge filter Δ pressure (clean filter at max power and normal temperature conditions)

•

GE recommends that operators set new lube scavenge temperature and scavenge filter ΔP control limits for alarm and automatic shutdown based on increases in temperature or filter ΔP relative to the established baseline.

Recommended Limits for:

Alarm

Shutdown

Lube Scavenge Temperature

Baseline +20°F (11°C)

Baseline +40°F (22°C)

Lube Scavenge Filter ΔP

Baseline +100%

Baseline +150%

7-3.4.1.2 Lube Supply Pressure at Pressure Tap vs. Gas Generator/Gas Turbine Speed Figures 7-5 (Sheet 1 of 4) through 7-5 (Sheet 4 of 4) provide nominal lube supply pressures at pressure tap vs. gas generator (GG)/GT speed and lube supply temperature for SAC models. 7-3.4.2

Air

Maximum airflow through the LM2500+ SAC engine is approximately 185 lb/sec (83.9 kg/sec) and is filtered by the inlet system to meet the following requirements:

•

95 percent of the time: must not contain solid particles exceeding 0.004 grains/1,000 ft³ (0.0003 g/28.32 m³)

•

5 percent of the time: must not contain solid particles exceeding 0.04 grains/1,000 ft³ (0.003 g/28.32 m³)

GEK 105054 Volume I

•

When operating in a marine environment, sodium (from air or water) entering the engine should not exceed 0.00045 parts/ million (ppm) average, or 0.003 ppm maximum

•

The maximum allowable liquid water content in the inlet air is 0.5 percent of the inlet airflow weight at inlet air temperatures of 42°F (5.6°C) and above. Below 42°F (5.6°C), no liquid water content is allowed

7-3.4.3

Gas Fuel

Gas fuel should be what is known in industry as dry gas. That is, the gasoline vapor in 1,000 ft³ (28.3 m³) of gas at standard conditions (60°F and 30 in. Hg abs [15.5°C and 764 mm Hg]) should not exceed 0.1 gal (0.37 l) of liquid. Liquid hydrocarbons in gas fuel can cause surges in operation or engine damage. Therefore, gas fuel mixtures must be maintained at temperatures 50°F (27.7°C) above their dewpoint at the engine fuel manifold inlet. The temperature of the gas fuel should not exceed 300°F (148.8°C) at the gas fuel manifold inlet. The requirements for natural gas are provided in Appendix A1. 7-3.4.3.1

Liquid Fuel

The requirements for liquid fuel are provided in Appendix A4. The fuel shall be filtered to 20 microns absolute. 7-3.4.4

NOx Suppression

The requirements for water or steam injection for NOx suppression are provided in Appendices A5 and A6.


GEK 105054 Volume I


Table 7-1. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines with 6-Stage Power Turbine Using MIL-L-23699 Oil NOTE The following values are for corrections to 9,000 rpm NGG and 150°F (66°C) lube inlet temperature. Read oil pressure and temperature then algebraically add the pressure additive as indicated for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure limit is 45-55 psig (310-279 kPa). Oil Supply Temp

Gas Generator Speed (RPM)

°F (°C)

8000

8100

8200

8300

8400

8500

8600

8700

8800

8900

100 (38)

- 7.74

- 8.93

-10.14

-11.35

-12.58

-13.81

-15.05

-16.31

-17.57

-18.85

9000 -20.14

110 (43)

- 3.52

- 4.64

- 5.76

- 6.89

- 8.03

- 9.18

-10.34

-11.51

-12.69

-13.88

-15.08

120 (49)

- 0.02

- 1.10

- 2.19

- 3.30

- 4.42

- 5.54

- 6.64

- 7.75

- 8.86

- 9.98

-11.11

130 (54)

+ 2.91

+ 1.93

+ 0.94

- 0.06

- 1.07

- 2.09

- 3.12

- 4.14

- 5.16

- 6.19

- 7.23

140 (60)

+ 5.82

+ 4.92

+ 4.01

+ 3.11

+ 2.19

+ 1.27

+ 0.33

- 0.60

- 1.55

- 2.50

- 3.46

150 (66)

+ 8.60

+ 7.77

+ 6.93

+ 6.09

+ 5.24

+ 4.38

+ 3.52

+ 2.65

+ 1.77

+ 0.89

160 (71)

+11.13

+10.34

+ 9.55

+ 8.75

+ 7.95

+ 7.14

+ 6.32

+ 5.50

+ 4.67

+ 3.84

0 +3.00

170 (77)

+13.35

+12.61

+11.87

+11.12

+10.33

+ 9.52

+ 8.71

+ 7.90

+ 7.07

+ 6.24

+5.40

180 (82)

+15.07

+14.33

+13.58

+12.83

+12.07

+11.31

+10.54

+ 9.77

+ 8.99

+ 818

+7.36

190 (88)

+16.53

+15.80

+15.06

+14.31

+13.55

+12.77

+11.98

+11.18

+10.38

+ 9.56

+8.74

200 (93)

+17.57

+16.84

+16.10

+15.35

+14.60

+13.83

+13.06

+12.27

+11.46

+10.65

+9.83

210 (99)

+18.40

+17.67

+16.93

+16.18

+15.42

+14.65

+13.88

+13.10

+12.31

+11.51

+10.71

220 (104)

+19.08

+18.36

+17.64

+16.90

+16.16

+15.41

+14.65

+13.89

+13.12

+12.34

+11.55

Oil Supply Temp


°F (°C)

9100

9200

9300

9400

9500

9600

9700

9800

9900

10000

100 (38)

-12.43

-22.74

-24.05

-25.37

-26.70

-28.04

-29.39

-30.76

-32.13

-33.50

110 (43)

-16.30

-17.52

-18.74

-19.99

-21.27

-22.56

-23.86

-25.18

-26.51

-27.85

120 (49)

-12.25

-13.39

-14.55

-15.17

-16.87

-18.05

-19.23

-20.42

-21.62

-22.83

130 (54)

- 8.28

- 9.33

-10.38

-11.43

-12.49

-13.56

-14.64

-15.72

-16.81

-17.91

140 (60)

- 4.43

- 5.39

- 6.36

- 7.33

- 8.31

- 9.30

-10.29

-11.29

-12.30

-13.31

150 (66)

- 0.09

- 1.81

- 2.72

- 3.64

- 4.56

- 5.49

- 6.53

- 7.37

- 8.32

- 9.27

160 (71)

+ 2.16

+ 1.31

- 0.46

- 0.40

- 1.27

- 2.16

- 3.09

- 4.02

- 4.96

- 5.91

170 (77)

+ 4.55

+ 3.70

+ 2.84

+ 1.99

+ 1.12

+ 0.25

- 0.62

- 1.05

- 2.39

- 3.28

180 (82)

+ 6.53

+ 5.69

+ 4.84

+ 3.99

+ 3.13

+ 2.24

+ 1.34

+ 0.43

- 0.48

- 1.41

190 (88)

+ 7.91

+ 7.08

+ 6.23

+ 5.38

+ 4.52

+ 3.66

+ 2.77

+ 1.86

+ 0.95

+ 0.03

200 (93)

+ 9.00

+ 8.16

+ 7.31

+ 6.45

+ 5.59

+ 4.72

+ 3.85

+ 2.96

+ 2.07

+ 1.17

210 (99)

+ 9.90

+ 9.08

+ 8.25

+ 7.42

+ 6.57

+ 5.72

+ 4.86

+ 4.00

+ 3.12

+ 2.24

220 (104)

+10.76

+ 9.95

+ 9.14

+ 8.33

+ 7.50

+ 6.67

+ 5.83

+ 4.98

+ 4.13

+ 3.26

NOTE:

Oil MIL-L-23699

Example:

Observed NGG 8700 RPM Observed Oil Pressure 56 psig (386 kPa) Oil Temperature 130°F (54°C) Pressure Additive -4.14 psig (28.5 kPa) Corrected Pressure 56 -4.14 = 51.86 psig (357.6 kPa)



GEK 105054 Volume I

Figure 7-1. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines with 6-Stage Power Turbine Using MIL-L-23699 Oil 7-7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I


Table 7-2. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines Using MIL-L-7808 Oil NOTE The following values are for corrections to 9,000 rpm NGG and 150°F (66°C) lube inlet temperature. Read oil pressure and temperature then algebraically add the pressure additive as indicated for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure limit is 37-45 psig (255-310 kPa). Oil Supply Temp


°F (°C)

8000

8100

8200

8300

8400

8500

8600

8700

8800

8900

9000

100 (38)

- 4.69

- 5.36

- 6.58

- 7.54

- 8.51

- 9.50

-10.48

-11.46

-12.44

-13.44

-14.43

110 (43)

- 1.72

- 2.58

- 3.45

- 4.32

- 5.20

- 6.08

- 6.97

- 7.87

- 8.78

- 9.69

-10.61

120 (49)

+ 1.08

- 0.29

- 0.51

- 1.32

- 2.13

- 2.95

- 3.77

- 4.61

- 5.44

- 6.29

- 7.14

130 (54)

+ 3.59

+ 2.84

+ 2.08

+ 1.32

+ 0.56

- 0.21

- 0.99

- 1.77

- 2.56

- 3.35

- 4.15

140 (60)

+ 5.79

+ 5.08

+ 4.34

+ 3.58

+ 2.82

+ 2.06

+ 1.28

+ 0.50

- 0.28

- 1.08

- 1.88

150 (66)

+ 7.41

+ 6.70

+ 6.00

+ 5.29

+ 4.57

+ 3.84

+ 3.11

+ 2.34

+ 1.57

+ 0.79

0

160 (71)

+ 8.79

+ 8.09

+ 7.38

+ 6.64

+ 5.90

+ 5.15

+ 4.40

+ 3.64

+ 2.87

+ 2.10

+ 1.31

170 (77)

+ 9.77

+ 9.07

+ 8.37

+ 7.65

+ 6.92

+ 6.17

+ 5.42

+ 4.66

+ 3.89

+ 3.11

+ 2.33

180 (82)

+10.55

+ 9.85

+ 9.14

+ 8.43

+ 7.71

+ 6.98

+ 6.24

+ 5.50

+ 4.75

+ 3.99

+ 3.22

190 (88)

+11.23

+10.55

+ 9.86

+ 9.16

+ 8.46

+ 7.75

+ 7.03

+ 6.30

+ 5.57

+ 4.83

+ 4.08

200 (93)

+11.89

+11.22

+10.55

+ 9.86

+ 9.17

+ 8.48

+ 7.78

+ 7.07

+ 6.35

+ 5.62

+ 4.89

210 (99)

+12.52

+11.87

+11.21

+10.54

+ 9.86

+ 9.17

+ 8.47

+ 7.76

+ 7.04

+ 6.31

+ 5.58

220 (104)

+13.08

+12.43

+11.76

+11.10

+10.42

+ 9.74

+ 9.05

+ 8.35

+ 7.64

+ 6.92

+ 6.19

Oil Supply Temp


°F (°C)

9100

9200

9300

9400

9500

9600

9700

9800

9900

10000

100 (38)

-15.44

-16.46

-17.46

-18.47

-19.50

-20.52

-21.56

-22.60

-23.65

-24.70

110 (43)

-11.53

-12.45

-13.37

-14.31

-15.24

-16.19

-17.14

-18.10

-19.07

-20.04

120 (49)

- 8.00

- 8.87

- 9.74

-10.61

-11.50

-12.39

-13.28

-14.18

-15.08

-15.99

130 (54)

- 4.95

- 5.76

- 6.57

- 7.42

- 8.29

- 9.17

-10.05

-10.94

-11.84

-12.75

140 (60)

- 2.67

- 3.48

- 4.29

- 5.10

- 5.92

- 6.75

- 7.58

- 8.43

- 9.31

-10.19

150 (66)

- 0.79

- 1.59

- 2.41

- 3.25

- 4.09

- 4.95

- 5.80

- 6.67

- 7.54

- 8.42

160 (71)

+ 0.52

- 0.27

- 1.08

- 1.90

- 2.75

- 3.59

- 4.45

- 5.32

- 6.19

- 7.07

170 (77)

+ 1.54

+ 0.74

- 0.07

- 0.88

- 1.70

- 2.53

- 3.37

- 4.21

- 5.06

- 5.92

180 (82)

+ 2.45

+ 1.67

+ 0.88

+ 0.09

- 0.71

- 1.52

- 2.34

- 3.16

- 3.99

- 4.83

190 (88)

+ 3.32

+ 2.56

+ 1.79

+ 1.01

+ 0.23

- 0.56

- 1.36

- 2.16

- 2.98

- 3.80

200 (93)

+ 4.15

+ 3.40

+ 2.64

+ 1.87

+ 1.09

+ 0.29

- 0.51

- 1.31

- 2.13

- 2.95

210 (99)

+ 4.84

+ 4.09

+ 3.34

+ 2.57

+ 1.80

+ 1.02

+ 0.23

- 0.58

- 1.39

- 2.20

220 (104)

+ 5.45

+ 4.71

+ 3.96

+ 3.20

+ 2.44

+ 1.66

+ 0.88

+ 0.09

- 0.70

- 1.51

NOTE:

Oil MIL-L-7808

Example:

Observed NGG 8600 RPM Observed Oil Pressure 40 psig (276 kPa) Oil Temperature 140°F (60°C) Pressure Additive +1.28 psig (8.8 kPa) Corrected Pressure 40 +1.28 = 41.28 psig (284.6 kPa)



GEK 105054 Volume I

Figure 7-2. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Turbines Using MIL-L-7808 Oil 7-9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I


Table 7-3. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generators Using MIL-L-23699 Oil NOTE The following values are for corrections to 9,000 rpm NGG and 150°F (66°C) lube inlet temperature. Read oil pressure and temperature then algebraically add the pressure additive as indicated for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure limit is 56-68 psig(386-469 kPa). Oil Supply Temp


°F (°C)

8000

8100

8200

8300

8400

8500

8600

8700

8800

8900

9000

100 (38)

-10.52

-12.01

-13.52

-15.04

-16.58

-18.12

-19.68

-21.25

-22.84

-24.43

-26.04

110 (43)

- 5.20

- 6.60

- 8.03

- 9.49

-10.98

-12.48

-14.00

-15.53

-17.07

-18.59

-20.10

120 (49)

- 0.99

- 2.30

- 3.62

- 4.96

- 6.29

- 7.64

- 9.01

-10.38

-11.77

-13.18

-14.56

130 (54)

+ 3.19

+ 2.02

+ 0.83

- 0.37

- 1.57

- 2.79

- 4.01

- 5.24

- 6.48

- 7.72

- 8.98

140 (60)

+ 7.26

+ 6.16

+ 5.05

+ 3.93

+ 2.80

+ 1.67

+ 0.52

- 0.63

- 1.80

- 2.97

- 4.15

150 (66)

+10.75

+ 9.71

+ 8.66

+ 7.61

+ 6.54

+ 5.47

+ 4.39

+ 3.31

+ 2.22

+ 1.11

0

160 (71)

+13.80

+12.83

+11.84

+10.79

+ 9.73

+ 8.65

+ 7.57

+ 6.48

+ 5.38

+ 4.27

+ 3.15

170 (77)

+15.99

+15.00

+14.01

+13.01

+12.00

+10.99

+ 9.97

+ 8.94

+ 7.87

+ 6.77

+ 5.66

180 (82)

+17.80

+16.77

+15.73

+14.67

+13.62

+12.55

+11.47

+10.38

+ 9.28

+ 8.17

+ 7.05

190 (88)

+18.85

+17.84

+16.83

+15.82

+14.79

+13.74

+12.69

+11.62

+10.55

+ 9.47

+ 8.37

200 (93)

+19.85

+18.87

+17.88

+16.88

+15.88

+14.86

+13.83

+12.79

+11.74

+10.68

+ 9.61

210 (99)

+20.79

+19.83

+18.87

+17.89

+16.91

+15.91

+14.91

+13.89

+12.87

+11.83

+10.79

220 (104)

+21.68

+20.75

+19.80

+18.85

+17.89

+16.91

+15.93

+14.94

+13.93

+12.92

+11.90

Oil Supply Temp


°F (°C)

9100

9200

9300

9400

9500

9600

9700

9800

9900

10000

100 (38)

-27.67

-29.30

-30.95

-32.61

-34.28

-35.96

-37.66

-39.37

-41.10

-42.85

110 (43)

-21.62

-23.15

-24.70

-26.25

-27.80

-29.38

-30.97

-32.57

-34.18

-35.80

120 (49)

-15.95

-17.35

-18.73

-20.11

-21.51

-22.93

-24.35

-25.78

-27.22

-28.67

130 (54)

-10.25

-11.52

-12.80

-14.10

-15.40

-16.72

-18.03

-19.36

-20.70

-22.05

140 (60)

- 5.43

- 6.54

- 7.75

- 8.97

-10.19

-11.43

-12.67

-13.92

-15.18

-16.45

150 (66)

- 1.11

- 2.23

- 3.36

- 4.50

- 5.64

- 6.87

- 8.11

- 9.36

-10.62

-11.88

160 (71)

+ 2.02

+ 0.88

- 0.27

- 1.41

- 2.56

- 3.72

- 4.89

- 6.06

- 7.25

- 8.44

170 (77)

+ 4.50

+ 3.33

+ 2.14

+ 0.93

- 0.28

- 1.49

- 2.72

- 3.96

- 5.21

- 6.47

180 (82)

+ 5.92

+ 4.77

+ 3.63

+ 2.46

+ 1.29

+ 0.10

- 1.10

- 2.31

- 3.53

- 4.76

190 (88)

+ 7.27

+ 6.15

+ 5.03

+ 3.89

+ 2.74

+ 1.58

+ 0.42

- 0.76

- 1.95

- 3.15

200 (93)

+ 8.54

+ 7.45

+ 6.34

+ 5.23

+ 4.11

+ 2.98

+ 1.84

+ 0.69

- 0.47

- 1.64

210 (99)

+ 9.73

+ 8.67

+ 7.59

+ 6.51

+ 5.41

+ 4.30

+ 3.19

+ 2.06

+ 0.93

- 0.21

220 (104)

+10.86

+ 9.80

+ 8.73

+ 7.64

+ 6.54

+ 5.43

+ 4.31

+ 3.17

+ 2.03

+ 0.88

NOTE:

Oil MIL-L-23699

Example:

Observed NGG 8700 RPM Observed Oil Pressure 56 psig (386 kPa) Oil Temperature 130°F (54°C) Pressure Additive -5.24 psig (36.1 kPa) Corrected Pressure 56 -5.24 = 50.76 psig (349.9 kPa)



GEK 105054 Volume I

Figure 7-3. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generator Using MIL-L-23699 Oil 7-11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I


Table 7-4. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generators Using MIL-L-7808 Oil NOTE The following values are for corrections to 9,000 rpm NGG and 150°F (66°C) lube inlet temperature. Read oil pressure and temperature then algebraically add the pressure additive as indicated for that particular rpm and lube temperature to the observed lube pressure. Corrected lube pressure limit is 47.5-58.5 psig (328-403 kPa). Oil Supply Temp


°F (°C)

8000

8100

8200

8300

8400

8500

8600

8700

8800

8900

9000

100 (38)

- 4.08

- 5.20

- 6.34

- 7.49

- 8.65

- 9.82

-10.99

-12.18

-13.37

-14.57

-15.78

110 (43)

+ 0.05

- 1.01

- 2.07

- 3.14

- 4.22

- 5.31

- 6.41

- 7.52

- 8.63

- 9.76

-10.89

120 (49)

+ 3.54

+ 2.54

+ 1.54

+ 0.54

- 0.48

- 1.50

- 2.53

- 3.57

- 4.61

- 5.66

- 6.72

130 (54)

+ 6.58

+ 5.59

+ 4.60

+ 3.59

+ 2.57

+ 1.55

+ 0.51

- 0.53

- 1.58

- 2.64

- 3.17

140 (60)

+ 8.65

+ 7.71

+ 6.77

+ 5.82

+ 4.87

+ 3.90

+ 2.88

+ 1.85

+ 0.80

- 0.30

- 1.40

150 (66)

+10.25

+ 9.27

+ 8.27

+ 7.27

+ 6.26

+ 5.25

+ 4.22

+ 3.18

+ 2.13

+ 1.07

0

160 (71)

+11.32

+10.36

+ 9.40

+ 8.42

+ 7.44

+ 6.45

+ 5.44

+ 4.43

+ 3.40

+ 2.37

+ 1.33

170 (77)

+12.33

+11.39

+10.45

+ 9.50

+ 8.54

+ 7.57

+ 6.59

+ 5.60

+ 4.60

+ 3.59

+ 2.58

180 (82)

+13.27

+12.37

+11.45

+10.52

+ 9.59

+ 8.64

+ 7.68

+ 6.72

+ 5.74

+ 4.75

+ 3.76

190 (88)

+14.19

+13.30

+12.40

+11.49

+10.58

+ 9.65

+ 8.72

+ 7.78

+ 6.80

+ 5.83

+ 4.83

200 (93)

+15.04

+14.15

+13.25

+12.34

+11.42

+10.49

+ 9.55

+ 8.60

+ 7.64

+ 6.67

+ 5.69

210 (99)

+15.71

+14.84

+13.95

+13.65

+12.14

+11.21

+10.27

+ 9.33

+ 8.37

+ 7.41

+ 6.43

220 (104)

+16.31

+15.44

+14.56

+13.67

+12.77

+11.86

+10.94

+10.00

+ 9.06

+ 8.11

+ 7.15

Oil Supply Temp


°F (°C)

9100

9200

9300

9400

9500

9600

9700

9800

9900

10000

100 (38)

-16.99

-18.22

-19.45

-20.70

-21.95

-23.21

-24.49

-25.76

-27.50

-28.35

110 (43)

-12.03

-13.18

-14.34

-15.51

-16.68

-17.86

-19.05

-20.25

-21.46

-22.67

120 (49)

- 7.78

- 8.89

- 9.93

-11.07

-12.24

-13.41

-14.60

-15.79

-17.00

-18.21

130 (54)

- 4.79

- 5.86

- 6.94

- 8.04

- 9.13

-10.24

-11.35

-12.48

-13.66

-14.85

140 (60)

- 2.52

- 3.65

- 4.78

- 5.94

- 7.09

- 8.25

- 9.41

-10.60

-11.79

-13.00

150 (66)

- 1.09

- 2.17

- 3.28

- 4.40

- 5.52

- 6.65

- 7.79

- 8.94

-10.11

-11.28

160 (71)

+ 0.27

- 0.79

- 1.87

- 2.95

- 4.05

- 5.15

- 6.27

- 7.39

- 8.53

- 9.67

170 (77)

+ 1.55

+ 0.51

- 0.54

- 1.60

- 2.67

- 3.74

- 4.83

- 5.93

- 7.03

- 8.15

180 (82)

+ 2.76

+ 1.74

+ 0.72

- 0.32

- 1.36

- 2.41

- 3.49

- 4.57

- 5.67

- 6.79

190 (88)

+ 3.82

+ 2.80

+ 1.78

+ 0.74

- 0.31

- 1.37

- 2.44

- 3.52

- 4.61

- 5.71

200 (93)

+ 4.69

+ 3.68

+ 2.65

+ 1.62

+ 0.58

- 0.48

- 1.54

- 2.62

- 3.70

- 4.80

210 (99)

+ 5.44

+ 4.44

+ 3.44

+ 2.42

+ 1.39

+ 0.35

- 0.69

- 1.75

- 2.82

- 3.90

220 (104)

+ 6.18

+ 5.20

+ 4.21

+ 3.20

+ 2.19

+ 1.17

+ 0.14

- 0.90

- 1.95

- 3.02

NOTE:

Oil MIL-L-7808

Example:

Observed NGG 8600 RPM Observed Oil Pressure 40 psig (276 kPa) Oil Temperature 140°F (60°C) Pressure Additive +2.88 psig (19.9 kPa) Corrected Pressure 40 +2.88 = 42.88 psig (295.6 kPa)



GEK 105054 Volume I

Figure 7-4. Lube Oil Pressure Correction for Industrial LM2500+ SAC Gas Generator Using MIL-L-7808 Oil 7-13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I


Figure 7-5. LM2500+ SAC Gas Turbine with 6-Stage Power Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-7808 Oil (Sheet 1 of 4)



GEK 105054 Volume I

Figure 7-5.LM2500+ SAC Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-7808 Oil (Sheet 2 of 4) 7-15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I


Figure 7-5. LM2500+ SAC Gas Turbine with 6-Stage Power Turbine Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-23699 Oil (Sheet 3 of 4) 7-16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


GEK 105054 Volume I

Figure 7-5. LM2500+ SAC Gas Generator Lube Supply Pressure at Pressure Tap vs Gas Generator Speed Using MIL-L-23699 Oil (Sheet 4 of 4)


GEK 105054 Volume I


7-3.4.5 Adjustment of Engine High Pressure Recoup Cavity Pressure Within Preferred Operating Range NOTE High pressure recoup should be checked at initial startup and periodically thereafter. Refer to Chapter 11, Table 11-1, and WP 417 00. Maintenance of engine high pressure (HP) recoup cavity pressure in the preferred operating range is required to ensure No. 4B bearing life. During initial buildup of engine, HP recoup cavity pressure was adjusted into the preferred operating range with the proper size metering spacers. Periodic plotting of the HP recoup cavity pressure is required in service, because seal leakage can change with operation of the engine and may cause HP recoup cavity pressure to fall outside the preferred operating range. Refer to WP 417 00 for procedure. 7-3.4.6

Adjustment of Power Turbine (PT) Thrust Balance Cavity Pressure Within Preferred Operating Range (6-Stage PT Applications Only)

Periodic plotting of the PT thrust balance cavity pressure is required in service because seal leakage can change with the operation of the engine. This may cause PT thrust balance cavity pressure to fall outside the preferred operating range. Refer to Volume II, WP 431 00, for procedure. 7-3.5

The engine and package should undergo a thorough prestart inspection during installation or after maintenance to ensure a troublefree transition from installation to full operation. This inspection will help to detect potential installation problems. The following inspections should be performed during installation of the engine in the enclosure: a.

Inspect the enclosure per the packager's instructions.

b.

Perform an external inspection. Ensure that all connections are tight and that no binding or chafing is evident on flexible electrical cables, hoses, or tubes.

c

Bonding straps are in place and secure.

d.

Inspect the engine inlet area. Thoroughly inspect the inlet plenum for dirt and foreign objects. Clean, vacuum, and/or wash the area as necessary.

e.

Inspect the exhaust system for foreign objects.

f.

Ensure that the lube system is properly serviced.

g.

Inspect for leaks in fuel and lube oil lines.

h.

Ensure CRF leakage ports, struts 7 and 10, are open (not capped)

i.

Ensure T5.4 thermocouple system functions properly.

j.

Ensure steam manifolds are aligned (if required).

NOTE PT thrust balance cavity pressure should be checked at initial startup and periodically thereafter. Refer to Chapter 11, Table 11-1, and Volume II, WP 431 00. Maintenance of PT thrust balance cavity pressure in the preferred operating range is required to ensure No. 7B bearing life. During initial buildup of engine, PT thrust balance cavity pressure was adjusted into the preferred operating range with the proper size orifice plate.

Initial Prestart Inspections



k.

Ensure steam HP recoup system is installed (if required).

l.

Ensure fire/alarm system is functional.

7-3.6

GEK 105054 Volume I

Initial Operational Checkout

1.

With ignition leads disconnected and fuel shutoff valves closed, make automatic start of GG per packager’s manual.

2.

GG should go through normal start cycle and then abort because of lack of flame/ignition.

CAUTION IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS BEING IMPOSED ON ENGINE COMPONENTS, WITH IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAILURE OF THE ENGINE.

e.

Perform prestart as follows:

The initial startup procedures described in this section should be followed after any engine installation, GG replacement, or major system or engine maintenance. The engine should be operated at various speed/load conditions in order to establish baseline performance for the specific installation. Refer to paragraph 7-4.4.1c. a. b. c.

Perform initial prestart inspection, per paragraph 7-3.5.

Motor the engine for 2 minutes per the packager's instructions and per Motoring in paragraph 7-4.3. During motoring, check for the following: Oil pressure indication

•

Lube oil leaks

•

Unusual noise during coastdown Perform false start as follows:

With ignition system disabled, but with fuel shutoff valve open and governing system operating, make automatic start of GG per packager’s manual.

2.

GG should accelerate to applicable light-off speed. Fuel valve should open and fuel manifold pressure should be verified. Start will then abort because of lack of flame/ ignition.

3.

Allow GG to coast to stop; then motor it to purge any remaining fuel from GG or drain liquid fuel from manifolds (if liquid fuel was used). Continue to motor for a minimum 60 seconds to purge fuel from GG. Consult packager’s manual for necessary prestart purge time.

Perform the following ignition system functional check:

Perform normal prestart checks, per paragraph 7-4.2.

•

d.

f.

1.

WARNING

•

IGNITION SYSTEM SHALL BE INOPERATIVE FOR AT LEAST 2 MINUTES BEFORE DISCONNECTING IGNITION LEADS. IGNITION SYSTEM COULD BE CHARGED WITH LETHAL HIGH VOLTAGE.

•

ENSURE FUEL VALVES ARE CLOSED THROUGHOUT THIS PROCEDURE. 7-19


GEK 105054 Volume I 1.

2.


To clear combustor of any residual fuel, motor GG for 1.0 minute; allow GG to coast down. If the package is equipped with the optional second ignition exciter, disconnect one ignition exciter input lead at exciter. Temporarily secure input lead away from the exciter.

3.

Turn on electrical power to ignition system. An audible report (approximately two sparks per second) should be heard when spark igniter fires.

4.

Turn off electrical power to ignition system. Reconnect input lead to exciter.

5.

If equipped, repeat steps 2, 3, and 4, disconnecting the input lead to the second exciter.

6.

•

Check all parameters and verify that values are within normal range per Table 7-5

•

Observe and record all results

•

Correct discrepancies prior to load application

i.

Operation to maximum power. 1.

Slowly increase control setting (refer to packager’s manual) to increase gas generator speed (NGG). After each 500 RPM increase, log all instrument readings, paying particular attention to variable stator vane (VSV) position and vibration. If variable stator system is not within limits, inspect it per WP 419 00. If vibrations are not within limits, consult local General Electric Company representative.

2.

Operate GG up to rated power. The GG’s output will normally be limited by compressor discharge pressure (PS3) or on extremely cold days corrected core speed. Hold at this power setting until engine stabilizes.

If an audible report is not heard on first or second igniters, check out system to isolate problem, and take appropriate corrective action. WARNING

NOTE

WHEN WORKING INSIDE OR NEAR THE ENGINE ENCLOSURE DURING OPERATION, OBSERVE THE SAFETY PRECAUTIONS DESCRIBED IN PARAGRAPH 7-2.

Normal operating parameter ranges and limits are shown in Tables 7-5 and 7-6. Refer to Tables 7-7 and 7-8, and the appropriate Addendum in Volume 1 when operating with NOx Suppression.

g.

Perform verification test per paragraph 7-3.7.

h.

Make a normal start (paragraph 7-4.4, Starting and Operation) and set power at idle. When the engine is stabilized at idle, do the following:

•

Check engine and supply systems for leaks

•

Check for loose parts, tubing, cabling, etc.

3.

Compare recorded readings to typical values in Table 7-5 and troubleshoot as required.

4.

Log all instrument readings once they stabilize.



7-3.7

Verification Test

If no verification test is specified by the packager, the verification test described below should be performed after the initial operational checkout (paragraph 7-4.6) has been completed. Record any abnormal condition and perform any needed corrective action. a.

GEK 105054 Volume I

Verify all service systems (electrical, air, fuel, lube oil, fire control, water, indicators, and controls) are checked out and ready for operation.

NOTE Optimization of control schedules via combustor mapping should be accomplished prior to operation at full power. e.

Restart the engine and slowly advance to full power. If the accel follows a cold start, it should be at a rate not to exceed zero to maximum load in less than 5 minutes. A ramped (constant rate) load increase should be maintained during the accel.

f.

Stabilize at full power for 3 minutes, then observe and record the data specified in Table 7-5, Typical Operating Levels.

b.

Make a start (paragraph 7-4.4, Starting and Operation).

c.

Hold at idle for 5 minutes minimum.

g.

Reduce power to idle.

d.

Perform PT overspeed shutdown test on each channel, with the PT unloaded, by slowly increasing power turbine speed (NPT) until automatic shutdown occurs. Shutdown should occur at appropriate trip speed for model. If automatic shutdown does not occur, shutdown manually and check speed indication and automatic shutdown systems.

h.

Perform a normal shutdown, (paragraph 7-4.5.1, Normal Shutdown).

i.

Inspect for leakage and loose parts and take any corrective action required.

j.

Check lube and scavenge pump screens for evidence of contamination.


GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7-5. Typical Operating Levels

Parameter T2, °F (°C) (Inlet temperature) P2, psia (kPa absolute) (Inlet pressure) NGG, rpm (Gas generator speed) PS3, psia (kPa absolute) CDP T3, °F (°C) (Compressor discharge temperature) WF36, lb/hr (kg/hr) @ 19,000 BTU/lb (10,555 kcal/kg) (Gas fuel flow) WF36, lb/hr (kg/hr) @ 18,400 BTU/lb (10,555 kcal/kg) PT5.4, psia (kPa absolute) (Power Turbine [PT] inlet pressure) T5.4, °F (°C) (see Figure 7-6) (PT inlet temperature) PT speed for 60 Hz (rpm) PT speed for 50 Hz (rpm) VSV position, degrees Lube supply pressure, psig (kPa gage) Lube supply temperature, °F (°C) Lube scavenge pressure, psig (kPa gage) Lube scavenge temperature (A/TGB-sump), °F (°C) (Note 8)

Max Operating Limit (Note 1) N/A

IDLE 40 to 70 (4.4 to 21.1) 14.5 - 14.8 (99.97 - 102.04) 5900 - 6100 (Note 2) 40 - 55 (275.8 - 379.2) 285 to 365 (140.6 to 184.9)

Max Power 40 to 70 (4.4 to 21.1) 14.5 - 14.8 (99.97 - 102.04) 9150 - 9600

10,050 (Note 3)

280 - 320 (1930.5 - 2206.3) 835 to 890 (446.1 to 476.6)

300-335 (Note 9) (2068.4 - 2309.7) 935 (501.6)

1200 - 1500 (544.3 - 680.4)

11400 - 14300 (5170.9 - 6485.4)

N/A

1200 - 1500 (544.3 - 680.4) 17 - 19 (117.2 - 131.0) 1150 to 1350 (621.1 to 732.2)

30 to 34 8 - 15 (Note 5) (55.2 - 103.4) 140 to 160 (59.9 to 71.1) See appropriate packager manual 10 to 30 (5.5 to 16.6)

N/A

N/A 60 - 70 (413.7 - 482.6)

N/A

1455 to 1520 (790.6 to 826.7) 0 - 3600 0 - 3000 4 to 8 20 - 60 (Note 5) 137.9 - 413.7) 140 to 160 (59.9 to 71.1) 5 - 100 (34.4 - 689.4) 30 to 65 (16.6 to 36.1)

1566 (Note 4) (852.2)

N/A 8 min (Note 6) (55.1 min) 200 (Note 7) (93.3) 110 (Note 7) (758.4) 340 (171.1)



GEK 105054 Volume I

Table 7-5. Typical Operating Levels - (Cont.)

Parameter Lube scavenge temperature (B-sump), °F (°C) (Note 8) Lube scavenge temperature (C-sump), °F (°C) (Note 8) Lube scavenge temperature (D-sump), °F (°C) (Note 8) Lube scavenge temperature (AGB), °F (°C) (Note 8) Gas manifold pressure, psig (kPa gage) Natural gas fuel manifold pressure, psig (kPa gage) (With or without water/steam injection for NOx suppression) Natural gas fuel manifold temperature, °F (°C) (Natural gas models only) Starter supply pressure (optional air/ gas starters only) Liquid fuel manifold pressure, psig (kPa gage) (Liquid fuel only models only) Liquid fuel manifold pressure, psig (kPa gage) (Liquid fuel and dual fuel, water injected models only) Liquid fuel manifold temperature, °F (°C) (Liquid fuel models)

IDLE 10 to 15 (5.5 to 8.3) 10 to 40 (5.5 to 22.2) 10 to 40 (5.5 to 22.2) -10 to 30 (-5.5 to 16.6) 40 - 50 (275.8 - 344.7)

Recoup pressure, psig (kPa gage)

See Chapter 11 NOTE 1:

Max Power 70 to 120 (38.8 to 66.6) 60 to 110 (33.3 to 61.1) 20 to 80 (11.1 to 44.4) 20 to 50 (11.1 to 27.7) 335 - 385 (2209.7 - 2654.4) 20 - 390 (137.9 - 2689.0)

Max Operating Limit (Note 1) 340 (171.1) 340 (171.1) 340 (171.1) 340 (171.1) N/A

-65 to 150 (-53.8 to 65.5) 35 - 40 psig (241.3 - 275.7 kPa) 150 - 900 psig (1034.2 - 6205.2) 0 - 395 (0 - 2723.4) 20° (above wax point of fuel) to 150 ° (11 to 65.5) See Chapter 11

See Chapter 11

Unless otherwise noted, limits are shutdown limits. Reference Chapter 9, Engine Troubleshooting for complete electronic control alarm and shutdown limits. NOTE 2: For T2 temperatures between -30°F (-34.4°C) and 130°F (54.4°C).


GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7-5. Typical Operating Levels - (Cont.)

Parameter

IDLE

Max Power

Max Operating Limit (Note 1)

NOTE 3: NGG limit at T2=59°F (14.9°C); otherwise limited to 9,563 - 10,100 rpm over T2 from 10° to 120°F (-12.2° to 48.8°C) range. Shutdown limit 10,200 rpm. NOTE 4: Shutdown limit 1,600°F (871.1°C). NOTE 5: Correct and establish normal lube pressure range per Chapter 5. NOTE 6: At NGG > 4,500 rpm. NOTE 7: Alarm only. NOTE 8: Increase in scavenge temperature over lube supply temperature. Alarm limit 300°F (148.9°C). NOTE 9: Shutdown limit is 375 psia (2,585.5 kPa absolute). Table 7-6. Limits and Operating Requirements Event/Item

Max Limits/Requirements

Max Time Allowed for Ignition

t > 10 seconds after fuel/ignition application (gas) t > 20 seconds after fuel/ignition application (liquid)

Max Time to Reach Starter Cutout

NGG > 4,500 rpm at t _ 90 seconds

Max Time to Reach Idle

NGG > 6,050 rpm at t _ 120 seconds

HP Rotor Vibrations

4 mils or 1.75 in/sec at > 125 Hz and 1.5 in/sec < 125 Hz

Fuel Supply Temperature (Gas)

< Tsv +20°F (11°C) min; > 300°F (148.8°C)

PT Rotor Vibrations

7 mils or 1.25 in/sec at 45 Hz and 0.75 in/sec < 45 Hz



GEK 105054 Volume I

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

Max Operating Limit Parameter Steam Pressure at Manifold Inlet Steam Supply Temperature at manifold inlet Steam Scheduling Relative to Fuel flow During Transients Steam Metering Valve Closing Time Steam Shutoff Valve Closing Time (GT only)

Min Operating Limit

Normal Operating Limit Remarks 400 psig (2,757.9 kPa)

960°F (515.5°C)

50°F (9.9°C) of Superheat See Appendix A6 < 100 ms < 1.0 sec NOTE 1:

The LM2500+ SAC steam injected GT does not require any particular minimum steam flow through the fuel nozzle steam manifold, however considerations must be given to the system external to the engine with respect to line lengths, volumes, pipe lagging, cooling air flow over the lines, etc., to prevent condensate from developing due to an inadequate superheat and/or insufficient flow through the external pipes and components. NOTE 2: This pressure is for sea level operation and must be corrected for altitude for each engine installation.

Table 7-8. Gas Turbine/Gas Generator Water Injection Limits for NOx Suppression

Parameter Water Pressure at Manifold Inlet Water Supply Temperature

Max Operating Limit 400 psig (2,757.9 kPa) 180°F (82.2°C)

Min Operating Limit

Normal Operating Limit Remarks

See Note 1 NOTE

Manifold shall be free of pressure pulsations in the 0 to 100 Hz range. The water must be controlled in a manner to prevent any sudden pressure spikes which could momentarily displace fuel.


GEK 105054 Volume I


Figure 7-6. Transient Temperature Limits (Typical)



7-4

ENGINE OPERATION

Operational procedures are also presented in this section. Prior to operation of the engine, the site operators should be thoroughly schooled in both normal and abnormal (emergency) operations and the control system action/reaction to these conditions. This section offers guidelines for tracking engine operation times and maintenance actions, a thorough history of the GT’s performance will aid in further operations and maintenance decisions. 7-4.1

Component Life/Repair Intervals

Safe operation of the LM2500+ SAC is dependent on properly scheduled maintenance, repairs, and component replacement. In order to properly track these conditions, packagersupplied time and event counters provide data for the parameters. Tracking instructions are TBD. 7-4.2

Prestart Checks

Consult the packager's manual for mandatory prestart procedures to ensure that packagerfurnished systems are activated and operational. Prior to any motoring or start sequence, GE suggests the following checks as a minimum:

•

All maintenance requirements or discrepancies are cleared and signed off

•

Ensure that the inlet and enclosure have been inspected and cleaned in accordance with instructions in the packager's manual

GEK 105054 Volume I

•

Fuel shutoff valves are closed

•

Ignition system is off

•

Lube tank level is full

•

Lube supply valves are open

•

Lube oil temperature is above 20°F (-6.7°C) for MIL-L-23699 or above -20°F (-28.9°C) for MIL-L-7808

•

T5.4 less than 400°F (204.4°C)

•

All switches and interlocks set for proper sequence to allow motoring

•

Fuel metering valve at start position

•

VSVs at scheduled position

•

Gas vent valves set for gas startup

•

Liquid drain valves closed at liquid startup

•

Fire alarm/extinguisher system activated

•

Required checks and inspections for GT electronic control have been performed in accordance with packager’s manual

Although not necessarily required as part of normal starting procedures, motoring is frequently used following maintenance to check the engine prior to making a start. Motoring is performed with the fuel shutoff valves closed.




Motoring Procedures CAUTION

IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS BEING IMPOSED ON ENGINE COMPONENTS, WITH IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAILURE OF THE ENGINE.

c.

7-4.4

FOR MAXIMUM SAFETY, OPERATING PERSONNEL SHOULD REMAIN CLEAR OF THE PLANE OF THE GG STARTER WHEN STARTING THE UNIT AND SHOULD REMAIN CLEAR OF THE GG PLANE DURING OPERATION, EXERCISING THE SAME CARE REQUIRED IN THE VICINITY OF ANY HIGH-SPEED ROTATING EQUIPMENT. ENTERING THE ENCLOSURE DURING OPERATION ABOVE IDLE SPEED IS NOT RECOMMENDED. PROLONGED EXPOSURE TO THE GG SOUND LEVELS MAY CAUSE HEARING LOSS. CAUTION

After all preliminary checks have been completed and lines flushed, GG can be motored as follows:

b.

•

IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS BEING IMPOSED ON ENGINE COMPONENTS, WITH IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAILURE OF THE ENGINE.

•

IT IS CRITICAL THAT THE COLD START PROCEDURE BE FOLLOWED; OTHERWISE, MAJOR ENGINE DAMAGE CAN RESULT.

Make ignition and fuel-gas supply systems inoperative as follows: Disconnect power supply to ignition unit(s).

(2)

Close manual shutoff valve(s) to fuel skids.

Motor GG until gas generator speed (NGG) stabilizes and check for oil pressure. If there is no indication of oil pressure, stop motoring. Loosen oil fittings at lube pump inlet to bleed air from system and ensure pump is primed. Starter should motor GG to minimum of 2,200 rpm at full supply pressure to starter.

Normal Starting Sequence WARNING

Be certain that checklists have been established for packager-furnished equipment. Consult the packager's manual for mandatory prestart procedures and make certain that the packager-furnished lube supply subsystem is activated and operational prior to any motoring or start sequence.

(1)

Starting and Operation

7-4.4.1

NOTE

a.

Repeat motoring and bleeding procedure until an indication of oil pressure appears.

a.

Ensure that all prestart checks have been completed.



CAUTION MODELS LM2500-PK-MD AND LM2500-PK-MDW ARE DESIGNED TO OPERATE ON 100 PERCENT LIQUID FUEL, 100 PERCENT NATURAL GAS OR A COMBINATION OF THE TWO. THE GAS TURBINES CAN BE STARTED ON EITHER NATURAL GAS OR LIQUID FUEL BUT NOT ON A COMBINATION OF THE TWO. WHEN OPERATING ON BOTH FUELS, NEITHER THE NATURAL GAS OR LIQUID FUEL FLOW SHOULD BE LESS THAN THE IDLE FUEL FLOW; I.E. IF OPERATING ON BOTH FUELS, THE MINIMUM FLOW TO THE GAS TURBINE WILL BE LIQUID FUEL IDLE FLOW PLUS NATURAL GAS IDLE FLOW.

GEK 105054 Volume I

•

Lightoff should occur in approximately 5 seconds

•

The PT rotor will start to rotate before the GG reaches idle speed

•

The engine will accelerate to idle (starterassisted to 4,500 rpm, where starter-cutout occurs)

•

Finish 5 minute warmup prior to loading

•

Check parameters per Table 7-5

•

Accelerate to desired load. Maintain a constant rate of load increase during acceleration. Stepped acceleration should be avoided

c.

Check and record the levels of the operating parameters designated in Tables 7-5 and 7-6. If all parameters shown in Tables 7-5 and 7-6 are normal, engine operation may continue. If engine parameters are outside the normal operating limits shown in Tables 7-5 and 7-6, troubleshoot and correct the problem per Chapter 9 before continuing.

NOTE

b.

•

A start may be aborted at any time by closing the fuel valve, allowing the gas generator to motor for 60 seconds, then closing the starter shutoff valve

•

When switching from liquid fuel burning to 100% natural gas burning, it is necessary to purge and cool the liquid portion of the fuel nozzles. Either natural gas or compressed air may be used to purge the fuel nozzles. Refer the packager’s manual. Engage the starter or initiate the start sequence. The following should occur:

•

The engine will begin to rotate and accelerate to greater than 1,700 rpm and stabilize

•

The ignition will be energized 2 minutes after reaching 1,700 rpm

•

The fuel shutoff valves will open

7-4.4.2

Hot Starts

a.

Starts indicating a T5.4 value in excess of 1,300°F (704.4°C) are considered to be hot starts. Normal starts are 1,000 to 1,200°F (537.7 to 648.8°C).

b.

Hot starts are typically the result of insufficient starter power, excess starting fuel flow, excessively high acceleration fuel flow rate, or open VSVs.

c.

If a hot start occurs, the startup procedure should not be repeated without investigating the cause of the hot start. For troubleshooting procedures, refer to Chapter 9




•

Shutdown NOTE

The information presented herein describes a typical sequence of events. However, for specific control sequencing modes and site operation information, see the packager's manual. The following types of engine shutdowns may occur: Normal shutdown: engine is taken off-line for a specific reason, annunciated fault, or other indication of problem which operator interprets as a reason for taking the engine offline or for reasons not necessarily related to the engine

Shutdown procedures are dependant on application. See packager’s manual. Under normal operating conditions, the engine is shut down in the sequence described below. a.

Normal Shutdown

•

HP rotor speed decreases to approximately 7,600 rpm (sync idle/min-load) over a 2 - 3 minute period

•

T5.4 decreases

•

Disconnection of generator from grid is initiated (where applicable)

CAUTION

•

THERMAL SEIZURE OF THE PT ROTOR CAN OCCUR WHEN A HOT GT IS SHUT DOWN AND IS MOST LIKELY TO OCCUR WITHIN 30 TO 40 MINUTES FOLLOWING GT OPERATION. THERMAL SEIZURE IS THE CONDITION WHERE THE PT ROTOR IS PREVENTED FROM ROTATING BY HARD CONTACT BETWEEN LPT BLADES AND SHROUDS, INTERSTAGE SEALS AND OTHER INTERNAL INTERFERENCE. THIS CONDITION IS THE RESULT OF UNEQUAL COOLING RATES OF THE VARIOUS PT COMPONENTS. THE POSSIBILITY OF THERMAL SEIZURES CAN BE REDUCED BY OPERATING THE GT AT IDLE POWER FOR AT LEAST 5 MINUTES PRIOR TO SHUTDOWN TO ACHIEVE PROPER COOLING OF THE PT.

Typical shutdown on electrical generator application: Power is retarded to minimum load (idle) or the control sequencer is activated to accomplish the shutdown. The following should occur:

Emergency shutdown: engine is taken offline by the operator or the control system to prevent damage or injury to equipment or personnel due to an engine or system fault. 7-4.5.1

FOR MODELS OPERATING ON 100 PERCENT LIQUID OR A RATIO OF LIQUID AND NATURAL GAS, IT IS NECESSARY TO DRAIN THE LIQUID FUEL MANIFOLD WHEN THE GAS TURBINE IS SHUT DOWN. THE MAXIMUM TEMPERATURE OF THE FUEL WILL BE 200°F (93.3°C). REFER TO PACKAGER’S MANUAL FOR PROCEDURE.

NOTE After shutdown, natural circulation of air through the engine must not be interrupted.

•

The engine should then decelerate to idle speed, approximately 6,000 rpm, where it should be allowed to cool for 5 minutes. After 5 minutes, the fuel shutoff valves should be closed and the drain valves opened.



b.

Typical shutdown on pumping application: Power is retarded to minimum load (idle) or the control sequencer is activated to accomplish the shutdown. The following should occur:

•

HP rotor speed decreases to approximately minimum load over a 2 - 3 minute period

•

T5.4 decreases

•

The engine should then decelerate to idle speed, approximately 6,000 rpm, where it should be allowed to cool for 5 minutes. After 5 minutes, the fuel shutoff valves should be closed and the drain valves opened.

7-4.5.2

GEK 105054 Volume I

a.

The fuel shutoff valves and metering valves are closed.

b.

Underspeed and oil pressure alarms are bypassed.

c.

Vent valves/drain valves are opened per control sequencing CAUTION

•

IF THE STEAM AND FUEL VALVES HAVE BEEN SHUT OFF SIMULTANEOUSLY DUE TO AN EMERGENCY CONDITION, SEQUENCING THE NORMALLY CLOSED DRAIN VALVE TO OPEN DURING SPEED ROLLBACK (PREFERABLY IN THE SUB-IDLE REGION) MUST BE ONE SUCH THAT A NATURAL PURGING OF THE MANIFOLD IS ACCOMPLISHED.

•

ASSURE FREEDOM OF ROTATION OF GAS TURBINE AFTER EMERGENCY SHUTDOWN FROM HIGH POWER SETTINGS. SEIZURE OF GAS TURBINE ROTOR MAY OCCUR DUE TO TIGHT CLEARANCES. NORMALLY THE ROTOR WILL FREE ITSELF AFTER A COOLING PERIOD OF 3 - 4 HOURS. CHECK FOR FREEDOM OF ROTATION BY TURNING ROTOR BY HAND.

Emergency Shutdown

In an emergency, the engine can be shut down from any power setting. This action can be initiated by the operator or by the packager-supplied control system. An emergency shutdown automatically initiates the following actions: NOTE

•

If emergency shutdown must be initiated while operating an engine equipped with optional NOx suppression on-line, the water and fuel valve can be shut off simultaneously. Action must be taken to purge the water from the fuel manifold at the earliest opportunity and prior to the next startup.

•

If emergency shutdown must be initiated while operating an engine equipped with steam or water injection for NOx suppression, steam/water metering valves and fuel shutoff valve must be closed rapidly. Failure to do so can result in high water/steam to fuel ratio in the combustor resulting in flameout.

Table 7-9 outlines the protection functions that require root cause resolution prior to engine motoring.


GEK 105054 Volume I


Table 7-9. Protective Function Causes Requiring Resolution Prior to Restart or Motoring Protective Function Excessive vibration alarm/shutdown Fire system shutdown and/or Halon release GT lube oil supply pressure low alarm/shutdown Lube scavenge alarm/shutdown Overspeed alarm/shutdown Lube filter pressure drop alarm/shutdown Enclosure high combustible gas level shutdown Lube scavenge pressure alarm Chip detector alarm Starter system failure Fail to crank indication Negative rate of change of PS3 (dPS3/dT) shutdown (stall indication)

7-4.5.3

Post-Shutdown Fire

During a normal shutdown, GG T5.4 should decrease following closure of the fuel shutoff valves. If T5.4 shows temperatures increasing after closure of fuel shutoff valves, combustion is still continuing. (Slight temperature increase after rotation stops is normal.) Ensure fuel is shut off, and motor the GG (paragraph 7-4.3). This will blow out the fire. As soon as temperature decreases to normal, discontinue motor. If condition persists refer to Chapter 9, Trouble-shooting. 7-4.6

b.

Motoring - Air or natural gas 5 minutes on, 2 minutes off, 5 minutes on, 18 minutes off for any number of cycles or 10 minutes on, 20 minutes off for any number of cycles. (For 10 minutes of motoring, maximum starter air inlet temperature is 200°F [93.3°C].)

c.

There is no duty cycle limit on the hydraulic starter as long as oil temperature is maintained below 140°F (59.9°C).

Starter Duty Cycle - Air, Natural Gas, or Hydraulic NOTE

Starter duty cycle applies only to GE supplied starters. a.

Starting - Air or natural gas 45 seconds on, 2 minutes off for any number of cycles or 2 minutes on, 5 minutes off, 2 minutes on, 21 minutes off for any number of cycles.



7-4.7

Restart CAUTION

IF A QUESTIONABLE CONDITION EXISTS, DO NOT ATTEMPT TO MOTOR OR OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION OF THE CONDITION HAS BEEN MADE. DO NOT RESTART ENGINE UNTIL CAUSES FOR ANY EMERGENCY SHUTDOWNS OR ABORTED OPERATIONS ARE THOROUGHLY INVESTIGATED AND CORRECTED. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS ON ENGINE COMPONENTS THAT MAY RESULT IN DAMAGE AND ULTIMATE FAILURE. This section addresses requirements for restarts after operation at power. Restarts may be initiated at any time if the prior shutdown sequence was normal. Restarts following an emergency shutdown or trip from operation at power may be restricted, depending on cause. 7-4.7.1

Hot Restarts

A restart following an emergency shutdown or trip from a power level where T5.4 is higher than 1,150°F (621.1°C) is considered a hot restart sequence and should not be attempted until the fault or circumstance triggering the shutdown is resolved. NOTE Conditions may not allow restarting or motoring in some situations, depending on the cause of the emergency shutdown or the status of the starting system. Reasons for not restarting or motoring the GT following an emergency shutdown are listed in Table 7-9. If the fault causing the emergency shutdown is fully understood, resolved, and cleared, and it has been verified that no damage to the engine has occurred, a restart or motoring sequence can be initiated, if the 10-minute limit has not been exceeded.

GEK 105054 Volume I

It is critical that the hot restart procedure follows a specific sequence to avoid major engine damage. The basic objective is to cool the high pressure turbine rotor (HPTR) and high pressure compressor rotor (HPCR) so blade tips maintain clearance with the more rapidly cooling cases. The restart procedure following a trip from power or an emergency shutdown (T5.4 greater than 1,150°F (621.1°C)) is as follows: An emergency shutdown must be followed by a restart or motoring cycle, if possible, to commence no more than 10 minutes after gas turbine high pressure (HP) rotor speed decreases below 300 rpm per paragraph 7-4.7.1.1. Conditions may not allow restarting or motoring in some situations, depending on the cause of the emergency shutdown or the status of the starting system. Reasons for not restarting or motoring the gas turbine following an emergency shutdown are listed in Table 7-9. If restart or motoring cannot be accomplished within 10 minutes, a mandatory lockout of 4 hours is enacted by the control system to allow sufficient component cooling to prevent possible damage to the engine per paragraph 7-4.7.1.2. 7-4.7.1.1 Restarts Within 10 Minutes After Shutdown a.

If circumstances permit the shutdown problem to be cleared within 10 minutes or less, and the HP rotor speed is less than 300 rpm, the restart procedure is as follows: (1)

Start the restart timer and initiate a manual restart purge. Reset all other timers as required.

(2)

Energize the starter to crank the HP rotor to a speed not to exceed 2,400 rpm for a minimum of 5 minutes. If the HP rotor rotates freely, make a normal start.


GEK 105054 Volume I (3)

(4)


If circumstances allow the HP rotor to be cranked within 10 minutes after shutdown, a manual purge, if available, will enable a restart purge cycle to be initiated. The restart purge cycle motors the engine HP rotor to prevent thermal bowing of the HP rotor.

a.

The GG may windmill for 2 weeks in duration at speeds below 100 rpm, provided each period is preceded by normal engine operation.

b.

The GG may windmill for periods up to 5 minutes at speeds between 100 rpm and 1,000 rpm, provided each period is preceded by normal engine operation.

By selecting the restart purge option, the operator preserves capability to restart the engine any time after the fault or system problem has been cleared.

7-4.7.1.2 Restart More Than 10 Minutes After Shutdown CAUTION BYPASSING THIS LOGIC AND CRANKING THE HP ROTOR MAY RESULT IN SEVERE HP COMPRESSOR RUBS AND MAY DAMAGE THE COMPRESSOR BLADES AND VANES. If it is not possible, or desirable, to initiate the restart purge cycle or a cool-down motoring cycle within 10 minutes after the HP rotor has coasted to below 300 rpm, the control system will then lock out any further attempts to restart or motor the engine for a period of 4 hours.

NOTE Adequate cooling of the oil must be provided at the higher free rotational speeds. Extended windmilling of the GG outside of the envelope described above may be carried out, but this requires additional equipment and protection. Contact GE Marine and Industrial Engine, Customer Service and Product Support, Cincinnati, Ohio 45215, for assistance. 7-4.9

Records and Running Logs

A log should be kept of all engine operation and/or running time. It is recommended that, as a suggested minimum, site operators should record the following:

•

Time of all starts and shutdowns

•

Total time for engine and site

•

After 4 hours, a normal start sequence may be initiated.

Reading of all engine instrument recordings, taken twice daily at the set-load point

•

All changes of engine speed and load

7-4.8

•

Brief statement of action taken in response to alarms or emergencies

•

Any system modifications, adjustments, or parts removal/replacement

•

Preventive or corrective maintenance activity

•

Installation/removal dates and operating hours for any spare or lease pool engine

Windmilling

Windmilling is generally caused by air forced through the inlet, causing the rotors to turn. Windmilling also occurs during shutdown as the kinetic energy of the rotor is dissipated by the pumping and rolling-element friction. The duration of GG windmilling is limited by the lubrication of its rotor bearings. The following defines these limits:



GEK 105054 Volume I

CHAPTER 8 Abnormal Operation 8-1

PURPOSE AND SCOPE

8-3.1

Alarms

This chapter covers abnormal operating conditions and procedures and control-provided automatic protective features. It provides definitions, descriptions, and operator actions required for abnormal conditions resulting in alarms or protective action. It also covers other conditions that do not trigger alarms or protective action, but which require special action by the operator.

Alarms are used to alert the operator to a condition that requires operator intervention. Alarms indicate that a condition has been reached that may lead to the initiation of a protective action, if not corrected immediately. Refer to the Troubleshooting Reference Table in Chapter 9 for the problem events and system conditions that trigger alarms and protective functions.

8-2

8-3.2

GENERAL DEFINITIONS

Abnormal operation is defined as any type of LM2500+ SAC operating condition that:

•

Deviates from normal operating limits.

•

Causes an alarm or other protective action to be initiated.

A protective action is defined as any action initiated automatically by the packager's control in order to:

•

Prevent damage to the LM2500+ SAC engine or installation.

•

Prevent injury to personnel.

8-3

CONTROL ACTIONS

The following are three levels of protection initiated by the LM2500+ SAC packagersupplied control system when abnormal conditions are sensed:

•

Alarms (alarm-only conditions)

•

Power cutbacks

•

Shutdowns

Power Cutback

There is only one power cutback function in the control. It initiates an alarm and a slow deceleration to minimum load (min-load). A slow deceleration to min-load is a controlled rate that allows all engine schedules and engine cooling to be maintained. Rather than decelerate all the way to idle, the engine decelerates to the min-load point. This allows the condition to be investigated without requiring a shutdown. There is no time limitation for remaining at min-load, unless the condition requiring this deceleration still persists, in which case, a normal shutdown sequence is initiated. 8-3.3

Shutdowns

There are five shutdown functions in the controls as follows:

•

Shutdown (gas turbine [GT] motoring allowed)

•

Emergency shutdown (GT motoring not allowed)

•

Step deceleration to idle/shutdown

•

Slow deceleration to idle/shutdown


8-1

GEK 105054 Volume I

•


Abort start/shutdown

These functions all initiate an alarm and a shutdown, but vary in their shutdown sequence. 8-3.3.1 Normal Shutdown A control initiated shutdown is a controlled deceleration to idle, a 5 minute stabilization period, a shutoff of the fuel valves, and opening of drain or vent valves. 8-3.3.2

Emergency Shutdown

A control initiated emergency shutdown occurs when the engine must be shut down immediately in order to prevent severe damage to the engine or installation. When an emergency shutdown occurs, the control initiates the following events: a.

The fuel shutoff valves and metering valve are closed.

b.


c.

Drain and vent valves are opened per control sequencing.

d.

Alarms, interlocks, sequence timers, and operating timers are reset. NOTE The emergency shutdown will not allow reset until gas generator speed (NGG) is less than 400 rpm.

Table 7-3 in Chapter 7 outlines the protection functions that require root cause resolution prior to engine motoring.

8-3.3.3 Step Deceleration to Idle/Shutdown A step deceleration to idle is an immediate rapid (max deceleration rate) deceleration to idle, followed by a 10 second pause, and then by a shutdown. A step deceleration provides a more controlled and orderly way of shutting down the engine than does an immediate shutdown at power. The 10 second pause at idle, allows various scheduled engine systems, such as variable stator vanes, to reach a stabilized condition before shutdown occurs. When a step deceleration occurs, the control initiates the following sequence of events: a.

Power is immediately reduced to idle, causing the engine to decelerate as rapidly as possible.

b.

When the engine reaches idle speed, the control holds it at idle for 10 seconds and then initiates a shutdown. The hold at idle allows the engine to be shut down from an on-schedule, stabilized condition.

c.

When the control initiates the shutdown after the 10 second idle hold, the following events occur:

•

The fuel shutoff valves are closed

•

Underspeed and oil pressure alarms are bypassed

•

Drain and vent valves are opened per control sequencing

•

Alarms, interlocks, sequence timers, and operating timers are reset

8-3.3.4 Slow Deceleration to Idle/Shutdown A slow deceleration to idle involves the fuel control controlling GT deceleration. After idle is reached, the sequence of events is as follows: a.

8-2

When the engine reaches idle speed, the control holds it at idle for 10 seconds and then initiates a shutdown. The hold at idle allows the engine to be shut down from an on-schedule, stabilized condition.



b.

When the control initiates the shutdown after the 10 second idle hold, the following events occur:

•

The fuel shutoff valves are closed

•

Underspeed and oil pressure alarms are bypassed

•

Drain and vent valves are opened per control sequencing

•

Alarms, interlocks, sequence timers, and operating timers are reset

8-3.3.5

Aborted Start/Shutdown

An aborted start is a shutdown that is initiated at any time during the start sequence when certain parameters exceed limits. During an aborted start, the control initiates the following events: a.

The fuel shutoff valves are closed.

b.

The ignition system and starter are deenergized.

c.


d.

Drain and vent valves are opened per control sequencing.

e.

Alarms, interlocks, sequence timers, and operating times are reset.

f.

A purge cycle is initiated by the control, if applicable.

GEK 105054 Volume I

8-4

OPERATOR ACTION

In order to avoid engine damage or more severe protective action, the operator must address the causes of all alarms and determine corrective actions necessary to clear abnormal conditions. Consult the troubleshooting procedures in Chapter 9 of this manual before resuming normal engine operation. After a power cutback or shutdown, positive action to correct the cause is necessary. For any alarm or protective action, the following general procedures should be followed: a.

Acknowledge the alarm in the manner specified in the packager's manual.

b.

During an alarm-only condition, correct the problem, if in question, contact packager/GE M&I, before resuming normal operation. NOTE Reduce power, then shut down and correct the problem; refer to the packager's manual for more specific information. Do not continue operation in the alarm condition.

c.

After a power cutback, correct the problem before resuming operation at power. If recovery is not possible, shut down and correct the problem.

d.

After a normal shutdown, correct the problem before attempting a restart.


8-3

GEK 105054 Volume I


IT IS CRITICAL THAT THE RESTART PROCEDURE, FOLLOWING AN EMERGENCY SHUTDOWN, FOLLOW THE SPECIFIC SEQUENCE OUTLINED IN CHAPTER 7 OF THIS VOLUME, SECTION 7-4.7.1, TO AVOID MAJOR ENGINE DAMAGE. e.

After emergency shutdown, correct the problem before attempting a restart. For restart procedure following an emergency shutdown, refer to Volume I, Chapter 7, Section 7-4.7.1 Hot Restarts.

f.

Enter appropriate comments in the engine log concerning any problems and corrective actions.

8-4.1

Special Gas Turbine Constraints NOTE

For GT’s with a 2-stage high speed power turbine (PT), refer to GEK 105052 for operating limits and troubleshooting for specific PT functions and conditions Under normal operating conditions, the gas generator (GG) is constrained by the operating limits published in the limits table in Chapter 7. Continuous operation between the alarm and shutdown or trip level should not be practiced. In the event that any of the following situations or events occur, the associated special action or limitation shall be followed in order to ensure the GG continued normal operation. These events may not be detected or may not be prevented by the customary protective devices of control systems:

•

Overtemperature during starting

•

Lube oil pressure

•

High speed stalls

•

Restart, following high power trip

8-4

•

No PT rotation

8-4.1.1 Overtemperature During Starting During starting and acceleration to idle, the cooling airflow to the components of the GG hot section are not sufficient to protect the metal at T5.4 alarm and trip levels specified in the limits table, refer to Chapter 7 (Engine Operation) and Chapter 9 (Troubleshooting). A lower T5.4 limit is therefore established, with higher levels acceptable, provided they exist for limited times. This shall be monitored by the operator. The over-temperature inspection, called for by entry into area B, requires hot section disassembly and inspection in a qualified facility. 8-4.1.2 Lube Oil Pressure The lube oil supply pressure limits given in the limit table (Chapter 7) are distress limits. Protective devices cannot reliably monitor supply pressure because the proper pressure is dependent on NGG, oil type, oil temperature, and number of oil jets. An operator must therefore derive a corrected oil pressure as directed on the appropriate pressure correction table (Chapter 7) to determine if the lube system is performing within the limits stated in each table. 8-4.1.3

High Speed Stall

The control system incorporates a stall detection feature that is intended to preclude continued operation in a stall condition, once a stall is detected. However, stalls incurred at GG rotational speeds above 7,500 RPM can result in compressor blade fracture. The GG can be operated after an inspection of compressor stages 3 through 6 verifies that blade tip clanging has not occurred. If tip clanging has occurred, further inspection and stress relief of the blades is required, which necessitates blade removal from the spool. It should be noted that a compressor stall may be secondary to another condition. A thorough inspection of the gas/turbine should be conducted before a restart is attempted.



GEK 105054 Volume I

8-4.1.4 Restart Following High Power Trip Restarts following an emergency shutdown or trip from operation at power may be restricted, depending on cause. Refer to Chapter 7, paragraph 7-4.7 for restart requirements. 8-4.1.5 No Power Turbine Rotation A thermally bound PT rotor could occur under extreme conditions following a rapid shutdown from high power. PT rotation should initiate during GT acceleration to idle. If rotation does not occur, the following procedure should be used: a.

Remain at idle for 30 seconds and shutdown.

b.

Restart and repeat step a.

c.

Restart and repeat step a.

d.

Restart and accelerate to 6800 rpm. Do not exceed 6800 rpm. Power turbine rotor should break away. If not, shut down and investigate for unlatched or shingled blades, or other cause.

Change 1

8-5/(8-6 Blank)



GEK 105054 Volume I

CHAPTER 9 Troubleshooting 9-1

PURPOSE AND SCOPE

This chapter provides general troubleshooting procedures for the LM2500+ SAC gas generator/turbine. 9-2

ARRANGEMENT AND USE

This chapter includes three major segments: Engine Troubleshooting, a Troubleshooting Reference Table, and a set of numbered Troubleshooting Procedures. For ease of use, the Troubleshooting Reference Table and Troubleshooting Procedures follow these introductory and explanatory sections. Figures and tables are presented at the end of the section. Figure 9-1 (Sheets 1 through 7) and Tables 9-1 through 9-10 provide supplementary information for some of the numbered Troubleshooting Procedures. 9-2.1

Engine Troubleshooting WARNING

IF A QUESTIONABLE CONDITION EXISTS, DO NOT OPERATE THE GAS GENERATOR/TURBINE UNTIL A THOROUGH INVESTIGATION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, OR OTHER RECOGNIZED PROBLEMS WITHOUT PRIOR THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS BEING IMPOSED ON GAS GENERATOR/COMPONENTS, WITH POTENTIAL IMMEDIATE OR SUBSEQUENT DESTRUCTIVE FAILURE OF THE GAS GENERATOR AND INJURY TO PERSONNEL.

CAUTION WHEN TROUBLESHOOTING ENGINE, DO NOT EXCEED MINIMUM AND MAXIMUM OPERATING LIMITS IN CHAPTER 7, TABLE 7-1. FAILURE TO COMPLY MAY CAUSE ADDITIONAL ENGINE MALFUNCTIONS. NOTE If troubleshooting procedures do not isolate and eliminate the fault, contact the Customer Service Department of General Electric Marine and Industrial Engines for assistance. 9-2.1.1

Introduction

Troubleshooting is a systematic analysis of symptoms that could indicate equipment malfunction. These symptoms usually appear as deviations from normal values of observed equipment parameters. Effective troubleshooting requires an intimate knowledge of the engine, its systems, and its interrelated effects. As a guide to intelligent troubleshooting, the most probable troubles and their possible symptoms are presented in this section. To assist in troubleshooting, operation of the packager’s controls should be understood. For this information, refer to packager’s instructions. Begin troubleshooting at the control panel for suspected engine faults. Trouble-shooter should be knowledgeable of the suspected troubled area. Troubleshooter should ensure the instruments used are calibrated and working properly, and have been accurately read and interpreted.


GEK 105054 Volume I


9-2.1.2 Gas Generator Speed Instrumentation Functional Check

9-2.3

a.

Check pin to pin resistance and pin to case of each sensor and each cable. See Tables 91 through 9-10.

b.

If sensor and cable resistances are within limits, check for proper gap setting on speed pickup. Refer to WP 105 00. If gap is out of limits, adjust and recheck voltage. If gap is within limits, replace pickup.

c.

Motor gas generator. At maximum motoring speed, voltage should be 30 - 70 volts peak-to-peak, sinewave at 10 kW load.

The Numbered Troubleshooting Procedures (TS-1 through TS-24) are referred to in the Troubleshooting Reference column of the Troubleshooting Reference Table. These procedures show symptoms for each engine or facility condition, possible causes for each, the troubleshooting procedure to isolate the cause of the problem, and the recommended corrective action. Events or conditions in the Troubleshooting Reference Table that have only a SPAM reference are not discussed in the numbered troubleshooting procedures.

d.

If cables and connectors are good, and installation gap is correct, check gas generator speed instrumentation at control system.

9-2.2

Troubleshooting Reference Table

The Troubleshooting Reference Table shows various problem events and system conditions, alarms, control actions, and the setpoints that trigger these alarms or control actions. These are grouped by major engine/facility systems. Each event also lists a numbered troubleshooting procedure (TS-) or a SPAM (See Packager's Appropriate Manual) reference. At the end of the Troubleshooting Reference Table are items in the Miscellaneous category. These either do not trigger an alarm or control action by themselves or are a combination of conditions. Some combinations may or may not trigger an alarm/control action by themselves, but must be looked at in combination with others.

Numbered Troubleshooting Procedures

Table 9-10 shows maximum allowable instrumentation and accessory temperatures. 9-2.4

Using This Chapter

The steps shown below illustrate how to use this chapter for troubleshooting. Example - Alarm received for overtemperature in lube scavenge system: a.

Find the lube system entry in the Troubleshooting Reference Table Contents on page 9-3 and refer to page listed.

b.

Refer to Troubleshooting Procedure Contents on page 9-18. Find TS-10, as listed in the Troubleshooting Reference column.

c.

Follow the appropriate procedure for each possible cause listed in TS-10. NOTE Symptoms, possible causes, troubleshooting procedures, and corrective actions are grouped horizontally across each page, allowing each symptom or set of symptoms to have more than one possible cause. Each possible cause may also have more than one troubleshooting procedure, and each troubleshooting procedure may have more than one corrective action.



GEK 105054 Volume I

Troubleshooting Reference Table Contents Page Combustion System............................................................................................................

9-4

Compressor System............................................................................................................

9-8

Facility System...................................................................................................................

9-4

Fuel System........................................................................................................................

9-5

Low Pressure Turbine Air Inlet Temperature System........................................................

9-12

Lube System.......................................................................................................................

9-10

Miscellaneous Systems.......................................................................................................

9-15

Power Turbine Speed Indication System (6-Stage Power Turbine).....................................................................................................

9-13

Starting System...................................................................................................................

9-14

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

9-16

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

9-7

Vibration Monitoring System............................................................................................

9-15


Alarm

System/Event

X

One Sensor X

Flame Loss, One or Both Sensors

Power Supply Failure (ECU)

Alarm

System/Event

Lose power for > 100 msec

Shutdown or Emergency Shutdown

Both Sensors

Shutdown or Emergency Shutdown Slow Deceleration to Minimum Load

Step Deceleration to Idle

Slow Deceleration to Minimum Load

Facility System


Combustion System

Troubleshooting Reference Table

X

Abort Start

Abort Start

7

Notes

7

Notes

SPAM

Troubleshooting Reference

TS-3 SPAM


In order to avoid engine damage or more severe protective action, the operator must address the causes of all alarms and determine corrective actions necessary to clear abnormal conditions before continuing engine operation. Except where otherwise indicated, each event shown in this Table is accompanied by an alarm, regardless of whether it is accompanied by a control action. Limits are shown in the alarm column for events resulting in an alarm only. Events that have both an alarm and an accompanying control action will show the limits in the appropriate action column and an X in the alarm column. In cases where one limit triggers an alarm only and a higher limit triggers both an alarm and control action, the limits for each will be shown in the appropriate columns. In any case that has no particular limits and is simply an either/or condition, the alarm and/or control action will be indicated by X in the appropriate columns.

Troubleshooting Reference Table GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

9-4


X

Fuel Supply Temperature, High

X

X

Loss of 1 Signal (Input: xxxAFAIL or xxxBFAIL)

Difference Fault (Input: xxx DFFAIL1)

Fuel Metering System

Fuel Supply Pressure (Upstream of Both Fuel Shutoff Valves), Low and High

Fuel Supply Pressure, Sensor Failure (Upstream of Both Fuel Shutoff Valves)

X

Alarm

Fuel Shutoff Valve Cycling

System/Event

X


> 350°F (177°C) Gas > 160°F (71.1°C) Liquid



Fuel System

> 350°F (177°C) Gas > 160°F (71.1°C) Liquid

X

Abort Start

Troubleshooting Reference Table - (Cont.)

24

7

4, 7

Notes

SPAM

SPAM

SPAM

SPAM

SPAM

TS-17 SPAM


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-5


One Sensor: < 10 psia, > 740 psia (< 69 kPa, > 5,102 kPa)

X

Servo Null Shift (Input: Servo Feedback)

Gas Pressure (Upstream of Metering Valve)

X

Servo Failure Open or Closed (Input: Servo Feedback)

SS Position Error (Input: I xxxDMD-xxxSEL

X (Steady State for > 0.5 sec)

Both Sensors: < 10 psia, > 740 psia (< 69, kPa, > 5,102 kPa)

E

E (Steady State for > 0.5 sec)

X

Position Error (Input: I xxxDMD-xxx-

SEL I

E

X

Loss of Both Sensors (Input: xxxAFAIL and xxxBFAIL)

E

X

Alarm

Difference Fault (Input: xxx DFFAIL2)

Fuel Metering System (Cont.)

System/Event




Fuel System - (Cont.)

Abort Start


7, 30

15

15

15

15

Notes

SPAM

SPAM

SPAM

SPAM

SPAM

SPAM

SPAM


GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

9-6


X

X

X

X Δ > 6.0%

Loss of Both Sensors (Input: VSVAFAIL and VSVBFAIL)

Position Error (Input: IVSVDMD - VSVSELI)

SS Position Error (Input: IVSVDMD - VSVSELI)

X < -2.0% or > 102%

Loss of 1 signal (Input: VSVAFAIL or VSVBFAIL)

Difference Fault (Input: VSVDFFAIL)

Alarm

System/Event

N Δ > 10%

N < -2.0% or > 102%


X

X

X Δ > 6.0 %



Variable Stator Vane System

Abort Start


12

11, 15

8, 15

6

2

Notes

TS-18

TS-18

TS-18

TS-18

TS-18



9-7


> 18°F (-8°C)

One Element: < -70°F, > 140°F (< -57°C, > 60°C)

< 8 psia, > 16 psia (< 35 psia, > 110 kPa)

< -40°F, > 1,200°F (< -40°C, > 649°C)

1 Sensor Element: > 40°F ( 22°C)

T2 A/B Difference Over Limit

T2 Sensor Failure, One or Both Elements

P2 Sensor Failure

T3 Sensor Failure

T3 Difference Over Limit

X

Stall

One Sensor: < 10 psia, > 480 psia (< 69 kPa, > 3,310 kPa)

PS3 Sensor Failure, One or Both Sensors

X

> 10 psia (69 kPa)

PS3 A/B Difference Over Limit

PS3 Over Pressure Limit

Alarm

System/Event

-dPS3/dt > Threshold for > 20 msec

> 375 psia (2,586 kpa)

Both sensors: < 10 psia, > 480 psia (< 69 kPa, > 3,310 kPa)

> 15 psia (> 103 kPa) for > 100 msec

Shutdown or Emergency Shutdown Step Deceleration to Idle

Both < -40°F, > 1,200°F (< -40°C, > 649°C)

Both Elements: < -70°F, > 140°F (< - 57°C, > 60°C)


Compressor System

Both

X

X

Abort Start


27

28

TS-7, TS-21

TS-7, TS-21

SPAM

TS-21

3, 9, 15 5

TS-21

TS-6

SPAM

SPAM

SPAM


27

7, 18, 19

7

3, 7, 30

7, 27

Notes


9-8


I A-B I > 37.5 rpm

NGG A/B Sensor Mismatch

26

26

7

Slow Acceleration to Maximum Power with High or Low T48

NGG Overspeed

X

26

26

10, 27

3, 7, 29

Notes

Acceleration to Maximum Power Not possible

X

X

Abort Start

Idle Speed Instability


19, 26

> 10,200 rpm

Both Sensors: < 0 rpm, < 1,700 rpm with > T48 > 400°F (204°C) and fuel on (Add > 11,500 rpm separately to each)


Idle Speed Too High or Low (NGGR)

> 10,100 rpm corrected

One Sensor: < 0 rpm, < 1,700 rpm with > T48 > 400°F (204°C) and fuel on

Gas Generator Speed (NGG) Sensor Failure, One or Both Sensors

No NGG Indication

Alarm

System/Event


Compressor System - (Cont.)


TS-16

TS-15

TS-15

TS-15

TS-15

TS-22

TS-22

TS-22



9-9


< 0 psig, > 140 psig (< 0 kPa, > 965 kPa)

> 200 F (93°C)

Lube Scavenge Pressure Sensor Failure

Lube Supply Overtemperature

24

> 110 psig (758 kPa) at NGG > 4,950 rpm

Lube Scavenge Pressure High

Lube Scavenge Pressure Low

SPAM

16, 24

< 0 psid, > 50 psid (< 0 kPa, > 345 kPa)

Lube Scavenge, Lube Supply, or VG Filter Diff Pressure Sensor Failure

9-10

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

SPAM

TS-11

TS-11

TS-21

3, 30

Both Elements: < -35°F, > 390°F (< -37°C, > 199°C)

One Element: < -35°F, > 390°F (< -37°C, > 199°C)

Lube Scavenge or Supply Temp Sensor Failure, Any Sensor (Any Sump, TGB Assy)

TS-10

TS-10

26

7

TS-9

TS-14

TS-14


Fluctuating Lube Scavenge Temp

X

> 300°F (149°C)

Lube Scavenge Overtemp (Any Sump, TGB Assy)

> 340°F (171°C)

16

> 20 psid (138 kPa)

Notes

Lube Scavenge, Lube Supply, or VG Filter Diff Pressure High (Impending Bypass)

Abort Start

26


26


High Oil Consumption

Alarm

Oil Contamination

System/Event


Lube System

Troubleshooting Reference Table - (Cont.) GEK 105054 Volume I LM2500+ SAC GE Industrial AeroDerivative Gas Turbines

N < 100 ohms N < 100 ohms N < 100 ohms N < 100 ohms

X

X

X

X

C-Sump Chip Detected (Input: CSUECDDET)

D-Sump Chip Detected (Input: DSUECDDET)

TGB Chip Detected (Input: TGBECDDET)

AGB Chip Detected (Input: AGBECDDET)

N < 100 ohms

X

< 90°F (< 32°C) at NGG > 6,050 rpm

Lube Supply Temp Below Min

< 0 psig, > 140 psig (< 0 kPa, > 965 kPa)

B-Sump Chip Detected (Input: BSUECDDET)

One Sensor: < -35°F, > 390°F (< -37°C, > 199°C)

Lube Supply Temp Sensor Failure

Lube Supply Pressure Sensor Failure

X

Both Sensors: < -35°F, > 390°F (< -37°C, > 199°C)

7, 24

Notes

GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page. 15

15

15

15

15

33

3

7, 24

25, 26

Abort Start

No Oil Pressure

< 6.0 psig (41 kPa) at NGG > 4,500 rpm


26

< 15 psig (103 kPa) NGG > 8,000 rpm < 8 psig (55 kPa) at 4,500 < NGG < 8,000 rpm

Lube Supply Pressure Low (With/Without Fluctuation)


Normal Lube Oil Pressure With Fluctuations > 5 psi

Alarm

System/Event


Lube System - (Cont.)


TS-14 SPAM

TS-14 SPAM

TS-14 SPAM

TS-14 SPAM

TS-14 SPAM

TS-12 SPAM

TS-21

SPAM

TS-13

TS-13

TS-13 SPAM



9-11

21, 22

10, 20, 22, 23

< -40°F ( -40°C) < 350°F, > 1,900°F (< 177°C, > 1,038°C)

I T max -T min I > 200°F (111°C)

Loss of Any Individual T48 Probe

T48 Difference

X < 400°F (< 204°C)

X

T48 Temperature Average (T48 Avg) Under Limit

< 400°F (204°C) for > 10 sec with Fuel on (Gas) or 20 sec (Liquid)

> 1,500°F (816°C) NGG < 5,000 rpm

7, 20

20

7, 20

X

> 1,600°F (871°C) for > 1.0 sec

Hot Start: T48 Start Temperature Over Limit

> 1,600°F (871°C) for > 1.0 sec

> 1,150°F (621°C) (3,600 rpm Power Turbine)

T48 Temperature Average (T48 Avg) Over Limit

Notes

24

Abort Start

< 10 psia, > 90 psia (< 69 kPa, > 621 kPa)


P5.4 Sensor Failure


26

Alarm

Post-Shutdown Fire

System/Event


Low Pressure Turbine Air Inlet Temperature System


TS-8

TS-8

TS-8 TS-19

TS-1

TS-8

SPAM

TS-2



9-12


One Sensor: < 0, < 1,000, > 4,500 rpm

NPT Sensor Failure

X

Alarm

System/Event

NPT Overspeed

< -40°F (-40°C) < 350°F, > 1,900°F (< 177°C, > 1,038°C) or T48 Difference > 350°F (177°C)


Slow Deceleration to Minimum Load Abort Start

> 3,960 rpm

Both Sensors: < 0, <1,000, > 4,500 rpm

Shutdown or Emergency Shutdown Step Deceleration to Idle


X

X Both Sensors

Abort Start

Power Turbine Speed Indication System (6-Stage Power Turbine)

< 0.5 + P2SEL psia NGGSEL > 6,050 rpm

PT48 Pipe Failure

T48 Overshoot or Fluctuation at High-Power Steady-State

X

Alarm

Loss of Any Four T48 Probes or Loss of Three Adjacent T48 Probes (Loss of T48 Avg)

System/Event


Low Pressure Turbine Air Inlet Temperature System - (Cont.)


7, 28

3, 7, 14, 17, 30

Notes

26

24, 36

20, 21, 22, 23

Notes

TS-16

TS-22


TS-8

SPAM

TS-8



9-13


T48 < 400°F (204°C) at t > 10 sec (Gas) t > 20 sec (Liquid)

Operator Monitored

Lube Supply Pressure High

NGG < 4,600 rpm at t > 90 sec

NGG < 1,700 rpm at t > 30 sec (Gas) t > 20 sec and < 1,200 rpm (Liquid)


Abort Start

Gas Generator Fails to Light Off

X

NGG Failure to Reach Starter Cutoff Speed



X

NGG Failure to Reach Fuel and Ignition Speed


Engine Fails to Motor/ No Indication of Motoring

X

Alarm

NGG Failure to Reach Idle Speed (Hung Start)

Starting Stall

System/Event


Starting System


25, 26

26

Notes

TS-19

TS-19

TS-13 SPAM

TS-19

TS-19

TS-19

TS-1 TS-6



9-14


> 4 mils DA or 1.5 in/sec (3.8 cm/ sec) below 125 Hz for > 1.0 sec > 1.75 in/sec (4.4 cm/sec) above 125 Hz for > 1.0 sec

> 7 mils DA or 0.75 in/sec (1.9 cm/sec) below 45 Hz for > 1.0 sec > 1.25 in/sec (3.2 cm/sec) above 45 Hz for > 1.0 sec

Alarm

High Vibes, Gas Generator Frequency

High Vibes, Power Turbine Frequency

System/Event





Miscellaneous Systems

> 10 mils DA or 1.5 in/sec (3.81 cm/sec ) below 45 Hz for > 0.1 sec > 1.75 in/sec (4.4 cm/sec) above 45 Hz for > 0.1 sec

> 7 mils DA or 2.5 in/sec (6.9 cm/ sec) below 125 Hz for > 0.1 sec> 3.0 in/sec (7.6 cm/sec) above 125 Hz for > 0.1 sec


Abort Start

Abort Start

Notes

Notes


TS-20

TS-20


TS-24

TS-2

High HP Rotor Speed, Low Power, and High or Low T48

Post-Shutdown Fire

29

TS-24

Loss of Performance

Events listed in this section are conditions that are not specifically handled by the engine control system or which are not part of any of the specific engine or package systems shown previously in this table. These events are either a single symptom or a combination of symptoms with no specific set of setpoints that can be monitored by the control. These events and conditions must be monitored by the operator and corrected as they occur. The combinations of conditions shown in this section do not cause any sort of alarm or control action to be initiated; however, individual symptoms that are part of any of the combinations shown here may cause an alarm or control action, just as they normally would when occurring alone (such as low pressure).

Alarm

System/Event


Vibration Monitoring System

Troubleshooting Reference Table - (Cont.) LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-15


Abort Start

Remove from average.

Control system defaults to remaining sensor/element.

Defaults to fully closed, zero fuel flow position.

Defaults to 14.69 psia (101.3 kPa).

> 1.0 second and NGGSEL > 4,950 rpm. Select lower sensor.

Emergency shutdown: Close fuel shutoff valves and CDP bleed valve.

Step to idle then shutdown. Set VSVMA to 0.0 mA.

Control system defaults to T2 = 115°F (46°C), if both sensors fail.

I Means Absolute Value I, the value of a number, regardless of a prefix plus or minus sign e.g., I -100I= 100.

> 1.0 second and NGGSEL > 4,950 rpm. Step to idle then shutdown. Set VSVMA to 0.0 mA.

> 5.0 seconds and NGGSEL > 4,950 rpm and I NGGDOT I < 150 rpm/sec and BRNDMD=BRNREQ for 5.0 seconds.

> 0.5 second, set VSVMA to 0.0 mA. Step to idle then shutdown.

NGG > 7,000 rpm for < 1,000 rpm/unit.

Shutdown: E: Emergency shutdown, N: Normal shutdown.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Troubleshooting Reference Table Notes


Limit and timer are adjustable.

Cavity Pressure < 50 psia (344.8 kPa) at P5.4 > 60 psia (413.7 kPa)

Low PT Thrust Balance Cavity Pressure


1.

Alarm

System/Event


Miscellaneous Systems - (Cont.)


Notes

TS-24



9-16


T48 is the average of individual T48 probe outputs, subject to rejection criteria of Note 24.

If < -40°F (-40°C), remove from average. Gas generator speed (NGG) > 5,000 rpm for < 350°F (177°C) limit.

Any T48 thermocouple probe reading is rejected from the T48 average calculation if it is:

20.

21.

22.

Reject from spread calculations any thermocouple probe reading that is out of range.

Defaults to last good value.

Reference Chapters 7 and 11 for normal/abnormal lube oil pressure determination.

This condition or combination of conditions requires operator intervention, but does not, by itself, cause the control system to initiate any sort of action.

Defaults to higher signal.

Failed element removed from average.

Defaults to 2,000 rpm, if both sensors fail.

Defaults to last good value, if both sensors fail.

NGG > 4,600 rpm for 0.5 second. NGGSEL > 4,950 rpm.

Defaults to minimum select.

Load addition inhibited by control at lube supply temperature less than 90°F (32°C).

Normal shutdown following deceleration to minimum load.

I Demand rate I < 50 percent per second.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

350°F (177°C) from T48 average

Refer to the appropriate packager's manual for control schedules, logic, and limits.

19.

(b)

Shutdowns caused by stall detection or variable-geometry system faults require borescope inspection of the gas generator. Refer to Volume II of this manual for inspection procedures.

18.

Out of range; T48i < 350°F(177°C) for NGG > 7,500 rpm or > 1,900°F (1,038°C)

This alarm/shutdown is enabled 60 seconds after reaching gas generator idle during the starting sequence.

17.

(a)

Alarm limits are based on component capability and may be reduced, consistent with the characteristics of each installation. For application and site specific conditions, refer to package’s manual.

16.

Troubleshooting Reference Table Notes - (Cont.) LM2500+ SAC GE Industrial AeroDerivative Gas Turbines GEK 105054 Volume I

9-17


GEK 105054 Volume I


Troubleshooting Procedure Contents Page TS-1:

Hot Start.......................................................................................................

9-19

TS-2:

Post-Shutdown Fire......................................................................................

9-20

TS-3:

Flameout.......................................................................................................

9-20

TS-4:

Electrical Power Supply Failure...................................................................

9-21

TS-5:

Fuel Supply Temperature.............................................................................

9-21

TS-6:

Stall..............................................................................................................

9-22

TS-7:

T3 (High Pressure Compressor Discharge Temperature)............................

9-23

TS-8:

T48 (LPT Inlet Temperature).......................................................................

9-24

TS-9:

Lube Supply/Scavenge Filter Differential Pressure....................................

9-25

TS-10:

Lube Scavenge Temperature.......................................................................

9-26

TS-11:

Lube Scavenge Pressure.............................................................................

9-27

TS-12:

Lube Supply Temperature...........................................................................

9-27

TS-13:

Lube Supply Pressure..................................................................................

9-28

TS-14:

Lube System - Miscellaneous......................................................................

9-31

TS-15:

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

9-33

TS-16:

Gas Generator and Power Turbine Overspeed............................................

9-34

TS-17:

Gas Fuel System Problems..........................................................................

9-34

TS-18:

Variable-Geometry Systems........................................................................

9-35

TS-19:

Miscellaneous Starting Problems................................................................

9-35

TS-20:

Engine Vibration.........................................................................................

9-40

TS-21:

Temperature Sensors...................................................................................

9-41

TS-22:

Speed Sensors.............................................................................................

9-42

TS-23:

Flame Sensor...............................................................................................

9-43

TS-24:

Miscellaneous Problems..............................................................................

9-43



GEK 105054 Volume I

Troubleshooting Procedures TS-1: Hot Start NOTE Do not repeat hot starts without prior thorough investigation. Symptoms

Possible Causes

Troubleshooting

Corrective Action

Starting stall; T48 increase plus NGG hang-up or dropoff

Excess starting fuel flow

SPAM: Check calibration of fuel flow

T48 high after lightoff and during first portion of start cycle

Acceleration fuel flows too high or low

SPAM: Check PS3 sensor system

T48 start temperature over limit

VSVs off-schedule

TS-18

T48 start temperature over backup start schedule limit

HPT severe degradation

Borescope engine per WP 406 00

Repair HPT, if out of specified borescope limits

Compressor dirty


Water-wash engine per WP 405 00

Compressor severe degradation


Repair HPT, if out of specified borescope limits

Fuel metering valve supply pressure exceeds upper/ lower limits

SPAM

Starter cutout speed too low

SPAM

Starter air/gas/hydraulic supply pressure too low (Starter should drive gas generator @ > 2,000 rpm)

TS-19

Any of the above

Perform engine overtemperature inspection per WP 412 00

NOTE Also see TS-6 for starting stalls.

Reset cutout setting or replace starter

SPAM: Check starter supply system regulation Replace engine, if out of specified overtemperature limits


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-2: Post-Shutdown Fire Symptoms T48 rise during normal shutdown T48 > 1,000°F ( > 538°C) after shutdown

Possible Causes

Troubleshooting

Corrective Action

Leaking fuel shutoff valve(s)

SPAM: Close valves, one at a time, to isolate faulty valve

Turn fuel off at isolation valve Motor gas generator with starter and ignition off until T48 indicates 400°F (204°C) or less. Do not exceed starter duty cycle Replace valves as required Borescope gas generator per WP 406 00, if T48 exceeds 1,000°F (538°C)

Sensor system failure

TS-21 TS-3: Flameout

Symptoms

Possible Causes

Troubleshooting

Corrective Action

TS-23

Flame loss, both sensors Flame loss


T48 < 400°F (204°C)

Low or no fuel flow or fuel pressure

SPAM: Check fuel system SPAM: Check PS3 sensor system

Fuel metering valve failed to close

SPAM

Fuel shutoff valves closed inadvertently and latched

SPAM: Check power to shutoff valve

Loss of T48 average signal in control

SPAM

SPAM Clean/replace as required



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-4: Electrical Power Supply Failure Symptoms No control indications

Possible Causes

Troubleshooting

Electrical power supply loss to control

SPAM

Component failure in power supply

SPAM

Corrective Action SPAM: Repair/replace power supply as required

TS-5: Fuel Supply Temperature Symptoms

Possible Causes

Troubleshooting

Corrective Action

Gas fuel below Tsv limit


SPAM

SPAM: Inspect fuel metering valve for hydrates

Fuel supply temperature high

Sensor system failure Fuel cooler system failure

If temperature exceeds 700°F (371°C), fuel system hose life may be affected SPAM

SPAM Replace hoses and other temperature-sensitive fuel system components per appropriate work package


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-6: Stall CAUTION BEFORE STARTING AN ENGINE THAT HAS EXPERIENCED A HOT START, A PRESTART MOTORING CHECK MUST BE PREFORMED TO DETERMINE IF FUEL MANIFOLD PRESSURE IS WITHIN LIMITS. REFER TO THE APPROPRIATE VOLUME 1, CHAPTER 7 AND ADDENDUM FOR SPECIFIC ENGINE MODEL BEING OPERATED. NOTE A starting stall is characterized by a hung start, slow acceleration to idle, lower than normal fuel manifold pressure (or fuel flow) and higher than normal power turbine inlet temperature (T48). Occasionally, the stall will continue at idle power. A stall at idle can be recognized by one or a combination of any of the following symptoms: higher than normal T48, higher than normal fuel manifold pressure, or NGG does not increase or is sluggish when power is advanced from idle. Symptoms Audible stall in operation Starting stall Shutdown with stall indication as first fault

Possible Causes All causes

Troubleshooting Borescope engine per WP 406 00

VSV system off- schedule VSV system worn/damaged

Inspect VSV per WP 414 00

Control system failure Starting system failure FOD

Ice on inlet screen or inlet bellmouth High inlet flow distortion Flooded plenum

Corrective Action Repair as required, if out of borescope inspection limits

TS-18

SPAM (Control System) SPAM

TS-19

Borescope engine per WP 406 00 Determine source of FOD Inspect inlet system per WP 401 00

Repair engine if out of borescope limits

Inspect inlet bellmouth screen and plenum Borescope engine for ice damage per WP 406 00 SPAM: Inspect antiicing system

Repair anti-icing system Melt ice with portable heater Repair compressor if damage is not within acceptable limits

CAUTION

BORESCOPE ENGINE BEFORE, RATHER THAN AFTER, WATERWASHING. WASHING BEFORE BORESCOPE MAY CAUSE ADDITIONAL DAMAGE, IF FOD ALREADY EXISTS.



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-6: Stall - (Cont.) Symptoms (Cont.) Audible stall Starting stall Shutdown with stall indication as first fault

Possible Causes

Troubleshooting

Corrective Action

Inlet restricted by foreign objects other than ice

Remove obstructions and check screen for damage. If there is the possibility that objects have passed through the screen, borescope engine for FOD per WP 406 00.

High or low fuel manifold pressure

TS-17

Dirty compressor

Inspect inlet per WP 401 00 Borescope HPC per WP 406 00


Internal distress not visible by borescope

All of the above

If all procedures above fail to show cause of problem, engine shall be replaced

TS-1

Repair compressor if FOD exceeds limits Clean inlet and collector

TS-7: T3 (High Pressure Compressor Discharge Temperature) Symptoms High T3 for power and T2 levels (all elements)

A/B difference over limit Sensor failure

Possible Causes

Troubleshooting

Corrective Action

Dirty HPC

Inspect inlet per WP 401 00 Borescope HPC per WP 406 00


Damaged HPC


Repair as required

Control system failure

SPAM: Check to see if engine is operating on PS3 on a hot day

SPAM


TS-21

Replace T3 sensor as required


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-8: T48 (LPT Inlet Temperature) Symptoms T48 average over limit

Possible Causes T48 system failure

Troubleshooting

Corrective Action

TS-21 SPAM

Single probe temperature over limit T48 max - T48 min spread exceeds 200°F (93°C)

T48 average under limit

Fuel nozzle condition

TS-21

HPC and HPT degradation Fuel supply pressure low (starting only) Excess fuel flow (starting only) Flameout

Borescope HPC and HPT per WP 406 00 SPAM

Repair or replace, as required, per WP 101 00. If hot T48, borescope HPT per WP 406 00 Repair as required

TS-3 SPAM

T48 system failure

TS-21 SPAM

Loss of average reading

T48 system failure

TS-21 SPAM

Loss of any individual probe(s) Higher T48 reading than previous reading at same power under same operating conditions; all other parameters changed with T48

Sensor failure(s) Cable failure(s) Control system failure VSV system off schedule

TS-21 SPAM

Replace probe/cable as required per WP 108 00

Check VSV system per

TS-18

Check T2 and TS-21 SPAM T48 sensor failure

TS-21

Compressor dirty

Inspect inlet per WP 401 00 Borescope HPC per WP 406 00 Borescope HPC and HPT per WP 406 00

FOD Hot section deterioration

Water-wash engine per WP 406 00 Repair/replace as required Repair/replace as required



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-8: T48 (LPT Inlet Temperature) - (Cont.) Symptoms

Possible Causes

T48 overshoot or fluctuation at high power steady-state

Troubleshooting

Sensor system or indicator failure

TS-21

Fuel supply system failure

Check fuel pressure

Worn or unstable fuel metering valve/control system

SPAM

Corrective Action

SPAM SPAM

TS-9: Lube Supply/Scavenge Filter Differential Pressure Symptoms High differential pressure alarm High differential pressure shutdown Increasing pressure drop with time Sensor failure: pressure less than zero or over sensor limits

Possible Causes Contaminated filter element

Troubleshooting

Corrective Action

Inspect filter per WP 400 00

Clean/replace filter element as required (for pump) per WP 400 00

Locate source of contamination

Correct source of contamination SPAM

Bearing or gearbox failure

Check pump screens and, if installed, check chip detectors per WP 400 00

Clean/replace pump screens and chip detectors as required (for pump) per WP 400 00


SPAM

TS-21 Increased oil viscosity or oil temp below normal

Check oil sample for viscosity per WP 407 00 SPAM: Check oil temp control valve

Replace oil, if necessary Repair as necessary


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-10: Lube Scavenge Temperature Symptoms

Possible Causes

Troubleshooting

Corrective Action

Shift in scavenge temperature - all sumps

High lube supply temperature

SPAM: Check lube oil cooler and control valve

Repair or replace per packager's manual

Shift in individual scavenge temperature > 30°F (17°C) at constant power

Bearing failure

Check lube and scavenge pump screens for bearing material per WP 400 00

Repair/replace engine as required


TS-21

Oil supply leak, internal or external Low oil supply pressure

Check for high oil consumption; check for external leak

Sump air/oil seal failure Loss of pressurization Overtemperature: dark oil in tank samples; burned odor; sludge and varnish on oil filter; sludge on chip detector

Repair leaks; repair or replace engine as required Repair or replace engine as required

Low oil level in lube tank

SPAM Check oil level in tank

Drain, flush clean, and service lube/hydraulic system and all filters

Degraded oil

Check oil sample

Clean chip detector as required per WP 400 00 Refill tanks to correct level; monitor scavenge temperature when operation resumes

Low oil flow in sumps

Check corrected lube supply per Chapter 5; check sump temperature rise

Replace engine as required

Degraded lube pump output

Check lube supply pressure

Replace pump per WP 102 00 (5 element) or SWP 102 01 (6 element) as required

Check supply side filter

Clean/replace oil filter as required

Lube and scavenge pump inlet screens clogged with carbon

Clean lube and scavenge pump inlet screens per WP 400 00 Determine and eliminate cause of contamination High oil supply temperature

TS-12

SPAM

Sump air/oil seal failure

Check individual sump temperatures to isolate area of failure

Repair or replace engine as required



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-10: Lube Scavenge Temperature - (Cont.) Symptoms Fluctuating lube scavenge temperature

Possible Causes

Troubleshooting


TS-21

Scavenge temp control valve cycling

SPAM

Corrective Action

TS-11: Lube Scavenge Pressure Symptoms Alarm on scavenge pressure Increasing scavenge pressure at constant power

Sensor Failure

Possible Causes Scavenge filter contaminated

Troubleshooting SPAM Check lube and scavenge pump screens per WP 400 00

Piping or heat exchanger fouled Scavenge interface not attached or obstructed Stuck check valve Improperly vented lube tank Cold oil

SPAM


SPAM

Corrective Action Replace filter as required per SPAM Determine and correct cause of contamination

SPAM Inspect check valve SPAM SPAM

Replace as required Warm oil with tank heater or by operating engine at low pressure

TS-12: Lube Supply Temperature Symptoms Overtemperature

Possible Causes

Troubleshooting

Oil cooler fouled Improper oil cooler temperature control

SPAM

High lube scavenge oil temperature

TS-10

Below minimum

Lube heater failure Improper oil cooler temperature control valve

SPAM

Sensor failure


TS-21

Corrective Action

SPAM


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-13: Lube Supply Pressure Symptoms High pressure

Possible Causes

Corrective Action

Low oil temperature

Run engine long enough to warm oil at low power SPAM: Check operation of lube oil cooler control valve and/or lube tank heater


SPAM

Oil line blockage or kink

Check for crimped or blocked oil supply tubes downstream of pressure tap SPAM

Replace or clean oil lines as required

Clogged oil lines and jets, often indicated by tendency of pressure to creep upward

Monitor scavenge oil temperature and record any abnormal temperature to isolate problem area. Check lube and scavenge pump screens and chip detectors per WP 400 00

Clean oil lines Replace engine

Low oil tank level

SPAM

Replenish

Oil leak

Check external components for leakage Check torque on all oil lines

Replace leaking components Retighten all loose fittings

Sensor failure

SPAM

Oil/water contamination

Check oil sample for milky appearance and for water content

SPAM Repair source of water entry into tank. Drain, flush, and refill oil system and clean or replace oil filters

Lube/scavenge pump relief valve failure

Check pump discharge pressure

Replace lube/scavenge pump per WP 102 00 or SWP 102 01

High supply filter pressure drop

SPAM: Check filter for contamination

NOTE Reference Chapter 7 for normal pressure which is a function of lube supply temperature, gas generator speed, lube oil type, and engine configuration.

Low pressure with fluctuation

Troubleshooting

SPAM



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-13: Lube Supply Pressure - (Cont.) Symptoms Low pressure - (Cont.)

Normal lube oil pressure with fluctuations > ±5 psi

NOTE Oil pressure fluctuation during transients is considered normal; however, the fluctuations should stop within 1 minute after a steady-state condition is established.

Possible Causes

Troubleshooting

Corrective Action

Obstructed or collapsed oil supply line to pump

Disconnect supply line at pump and check flow

Replace supply line

Check oil-in flex hose for deterioration

Replace oil-in flex hose

Check for obstruction in pump inlet

Remove obstruction from pump Replace lube/scavenge pump per WP 102 00 or SWP 102 01 as required

Internal oil leak (possible damage to oil seals)

Check for high oil consumption, drains, and frame vents Check for abnormal scavenge temperatures


Lube/scavenge pump failure

Check lube discharge for oil flow Pump drive spline

Replace lube/scavenge pump per WP 102 00 or SWP 102 01


SPAM

Low oil tank level

SPAM

Oil/water contamination

Check oil sample for milky appearance and water content

Repair source of water entry into oil tank. Drain, flush, and refill oil system with fresh oil. Clean or replace oil filters

Clogged filter

Check oil filter ΔP

SPAM


SPAM

Blocked or defective pump inlet line

Disconnect supply line at pump and check flow

Replace supply line

Check oil-in flex hose for deterioration

Replace oil-in flex hose

Check for obstruction in pump inlet

Remove obstruction from pump Replace lube/scavenge pump per WP 102 00 or SWP 102 01 as required


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-13: Lube Supply Pressure - (Cont.) Symptoms (Cont.) Normal lube oil pressure with fluctuations > ±5 psi

Possible Causes

Troubleshooting

Defective lube/scavenge pump relief valve

Defective oil tank vent

Replace lube/scavenge pump per WP 102 00 or SWP 102 01 as required SPAM

Air-in system lines No oil pressure

Corrective Action

Run engine to purge air

Lube/scavenge pump failure Sheared pump shaft

Verify lube supply to pump. Check lube or scavenge discharge for oil flow Check for NGG indication while motoring engine

Replace lube/scavenge pump per WP 102 00 or SWP 102 01 Replace pump if NGG indication is present with no oil pressure and normal oil supply to pump

Low oil tank level

SPAM

Faulty oil pressure indication; faulty transmitter or pressure line

SPAM

Obstructed oil supply line to pump

Disconnect supply line and check for presence of oil Check oil supply flex hose for deterioration (collapsed or kinked) Check for obstruction in pump inlet Check for improperly connected lines or reversed check valve

Continue troubleshooting Replace hose Remove obstruction and clean tank Correct problem

Obstructed tank strainer

Remove inlet strainer and inspect for obstructions

Remove obstruction and clean oil strainer and tank

Loss of pump prime

Check pump inlet line for presence of oil

Fill oil line with oil as required



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-14: Lube System - Miscellaneous Symptoms Oil contamination

Possible Causes Maintenance error; lube tank serviced with contaminated oil

Troubleshooting Contact GE M&I Customer Service before continuing operation

CAUTION If engine is operated for more than 200 hours with lubricating oil containing more than 5% mineral oil, significant internal sump coking may occur.

Corrective Action Flush all lube and hydraulic systems until samples are clear of contaminants Completely drain oil tank and as many service lines as possible. Service with fresh lubricating oil and circulate system until clear of contaminants. Drain oil tank and lines and refill with fresh oil Motor engine and operate for 24 hours and re-sample oil to confirm cleanliness

Lube/scavenge pump failure Hydraulic pump failure

Check lube and hydraulic screens and system filters for debris per WPs 400 00 and 408 00

Flush lube and hydraulic systems Replace defective hydraulic pump per WP 120 00 or lube/scavenge pump per WP 102 00 or SWP102 01 as required

Engine bearing failure Starter failure

Check all scavenge screens, chip detectors, and system filters for debris (bearing debris plus increased engine vibration) per WPs 400 00 and 408 00

Flush lube and hydraulic systems Replace engine as required Replace starter as required

Defective oil cooler/heat exchanger

SPAM

Water-wash engine per WP 405 00 Tighten coupling nuts or replace defective parts as required

Oil tank not clean

SPAM

External piping degradation/corrosion

SPAM


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-14: Lube System - Miscellaneous - (Cont.) Symptoms High oil consumption

Possible Causes

Troubleshooting

Corrective Action

Records in error

Verify records

Correct records

Oil leak from combined actuator drain, lube pump, accessory drive pad drains, combined drain B- and C-sumps, starter drain, or external lines

Isolate source Maximum B-/C-sump drainage is 7.0 cm³/hr Maximum AGB pad, starter, actuator, and lube drainage is 7.0 cm³/hr

Isolate each individual drain from the gang drain to find source of leakage. Repair as required

Air/oil separator failure

Inspect lines, drains, and air discharge (no oil discharge expected)

Clean or replace as required per WP 116 00

Sump pressurization tube or vent line blockage or damage

Inspect all pressurization tubes and vents

Clean or replace as required

Lube pump failure (flooded sump)

Inspect pump and check discharge pressure per WP 400 00

Replace lube/scavenge pump per WP 102 00 or

Internal leakage

Inspect (borescope inspect) flowpath per WP 406 00 Inspect bellmouth per WP 401 00 Inspect exhaust per WP 404 00

Repair or replace

External leakage in off-engine system

SPAM

SWP 102 01



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-15: Gas Generator (NGG) Speed Symptoms

Possible Causes

Troubleshooting

Sensor mismatch No speed indication

Sensor system failure Sensor gap too large

TS-22

Idle speed too high/low

Stall

TS-6

T2 sensor failure

TS-21

Control failure

SPAM

Speed sensor system failure

TS-22

Fuel metering valve failure

SPAM

Fuel system failure

TS-19

VG system off schedule

TS-18

Gas fuel properties not constant

SPAM

Fuel metering valve/ECU failure

SPAM

Fuel supply pressure fluctuation

SPAM

Intermittent T2, NGG, or PS3 sensor output

TS-21 TS-22

Idle speed instability

SPAM

Corrective Action Replace sensor Reset to correct gap Replace sensor

SPAM: PS3 Accel to maximum power not possible or accel slow

Low or no fuel flow and fuel pressure

SPAM: Check - PS3 line to sensor - PS3 sensor circuit - Fuel flow vs PS3 schedule

VG system off-schedule

TS-18

Control system failure

SPAM

SPAM


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-16: Gas Generator and Power Turbine Overspeed Symptoms NGG overspeed

Possible Causes

Troubleshooting

Control failure (without shutdown)

Perform overspeed inspection per WP 411 00 SPAM


TS-22

Corrective Action Replace gas generator, if damage exceeds limits SPAM

SPAM

NPT overspeed

Worn or unstable fuel metering valve

SPAM

Radial drive shaft failure

Attempt manual engine rotation from maintenance crank pad on aft end of TGB Assembly. View HPC rotor through borescope port per WP 406 00 to see if HPC rotates

Isolate and replace defective drive component per WP 207 00

High-speed coupling shaft failure

SPAM

SPAM

Control failure

Perform overspeed inspection per WP 411 00

Replace power turbine, if damage exceeds limits


TS-22 SPAM

TS-17: Fuel System Problems Symptoms

Possible Causes

Troubleshooting

Shutoff valve cycling

Control failure Valve failure Valve power failure

SPAM

Fuel manifold pressure too low at start

Fuel shutoff valve failure

SPAM

Fuel manifold pressure too high or low at power Speed/power instability

Fuel supply system failure

SPAM

Corrective Action



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-18: Variable-Geometry Systems Symptoms Position error Schedule limits exceeded

Possible Causes

Troubleshooting

Corrective Action

Low or no hydraulic pressure

Replace VSV control per WPs 100 00, 120 00, 121 00, and SPAM Replace VG pump per WP 120 00

Clean or replace filters/screens as required

LVDT or actuator failure

Check for open circuit

Replace actuator per WP 100 00

Binding in VSV system

Check per WP 418 00

Replace torque shaft per WP 114 00 as required

ECU

SPAM

TS-19: Miscellaneous Starting Problems Symptoms

Possible Causes

No start

Troubleshooting Reset control to get start permissive

Corrective Action SPAM

NOTE Deenergize ignition system and motor engine per packager's instructions to purge any gas in ducting. Do not exceed starter duty cycle if applicable. No start: NGG and fuel pressure OK

No start: NGG and ignition OK, but low or no fuel manifold pressure

Faulty ignition circuit(s)

Perform ignition system functional check per WP 409 00 SPAM

Repair or replace as required SPAM

Incorrect fuel quality

SPAM

Fuel supply pressure failure Fuel metering valve too far closed

Check vent valve positions Check fuel system pressures

SPAM: Correct as required

Fuel shutoff valves closed

Check fuel shutoff valve positions

Open fuel valves


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-19: Miscellaneous Starting Problems - (Cont.) Symptoms

Possible Causes

Troubleshooting

Corrective Action

No start: NGG and ignition OK, but low or no fuel manifold pressure (Cont.)

Fuel system contamination

Disconnect supply lines and check for clogged upstream filters and/or contamination in supply lines

Flush contaminants from fuel supply lines Clean upstream filters

No start: NGG rises rapidly to starter cutout speed

Sheared radial drive shaft, or IGB spline sheared

Crank engine from maintenance pad on aft end of TGB assembly. View rotor through borescope port per WP 406 00 to see if HPC rotates


Failure to light off

Same as above

Same as above

Ignition system failure

Perform ignition system functional check per WP 409 00 SPAM

Low starter air, gas, or hydraulic pressure output

SPAM


TS-22

Radial drive shaft or starter failure

Check drive shaft and starter SPAM

Low or no fuel flow and fuel pressure

SPAM: Check -PS3 line to sensor(s) -PS3 sensor circuit -Fuel flow vs PS3 schedule

Fuel contamination

Disconnect supply lines and check for clogged upstream filters or air and/or contamination in supply lines

VG position off-schedule

TS-18

Failure to reach idle speed on start (hung start) Failure to reach starter cutout speed Failure to reach fuel and ignition speed on start

NOTE The above symptoms may be accompanied by low fuel flow and low T48.

Replace igniters per WP 103 00 SPAM

SPAM Service, repair, or replace starter (GE only) per WP 117 00 SPAM Repair or replace radial drive shaft per WP 207 00

Flush contaminants from fuel supply lines Clean upstream filters



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-19: Miscellaneous Starting Problems - (Cont.) Symptoms Failure to reach idle speed on start (hung start) (Cont.)

No start, no NGG indication, no oil pressure

Possible Causes

Troubleshooting

Corrective Action

HP compressor damage

Borescope per WP 406 00


Start stall/hot start

TS-1 TS-6

Starter air, gas, or hydraulic pressure below limits Starter inoperative

SPAM: Check starter air, gas, or hydraulic supply pressure Check starter spline drive

Increase pressure to proper limit, or replace starter if pressure is OK

Faulty starter gas, air, or hydraulic shutoff valve

SPAM: Check starter gas, air, or hydraulic valve control voltage and valve pressure

Restore power supply or replace faulty component

Faulty start selector switch or open circuit breaker

SPAM: Check start selector switch and circuit breaker

Replace switch and/or reset circuit breaker

Seized gas generator rotor

Check rotor rotation with starter or with ratchet wrench on TGB assembly maintenance crank pad

Attempt another start after cool-down period and/or rotation check

Borescope for evidence of damage to HPC/HPT per WP 406 00


Check for binding, rubs, etc. Check chip detectors and scavenge screens per WP 400 00


GEK 105054 Volume I



Possible Causes

Troubleshooting

Corrective Action If vane has become disengaged or rotated and has grooved HPC rotor, vane shall be removed and replaced per WP 212 00. Depth of the HPC rotor groove shall also be inspected. If groove is through the alumina coating, gas generator shall be replaced

No start, no NGG indication, no oil pressure (Cont.)

Seized gas generator rotor

Check VSV system for mechanical integrity; verify that there is no vane rotation and that no vane tip is digging into HPC rotor

No start, no NGG indication

NGG sensor system failure

TS-22

Engine fails to motor, but control indicates motoring; rapid increase in indicated motoring speed

Radial drive shaft failure

Attempt manual rotation through maintenance crank pad on aft end of TGB assembly. Borescope per WP 406 00 to see if HPC rotates


Engine fails to motor/no indication of motoring or fails to reach maximum motoring speed

Seized engine

For cold engine, check rotation with starter or with ratchet wrench on TGB assembly maintenance crank pad Borescope engine per

Attempt another start and/or rotation check after 30 minute cool down period Repair or replace engine

WP 406 00

If installed, check chip detectors per WP 400 00 GG speed sensor engagement incorrect

Check sensor gap per WP 105 00

Repair or replace as necessary per WP 105 00


TS-22

Repair or replace as required



GEK 105054 Volume I


Possible Causes

Troubleshooting

Corrective Action

Engine fails to motor/no indication of motoring or fails to reach maximum motoring speed - (cont.)

Low starter supply pressure Starter exhaust blockage (pneumatic starter)

SPAM

Starter failure

Attempt manual engine rotation through gearbox; if engine rotates, problem is in starter system

Service, repair, or replace starter per WP 117 00 or SWP 117 01 (GE starter only); otherwise, SPAM

Accessory failure

Remove gearbox-driven accessories one at a time and attempt manual engine rotation, after each accessory is removed

If engine will rotate after removal of an accessory, replace the failed accessory

Accessory gearbox failure

If engine will not turn after removal of all accessories, remove radial drive shaft per WP 207 00. Rotate accessory gearbox

Replace accessory gearbox per WP 206 00

FOD

If starter and drive train operate properly, but engine will not rotate, borescope engine per WP 406 00


Bearing or seal failure

Check chip detectors for debris; check sump scavenge screen in lube and scavenge pump for evidence of bearing or seal failure



GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-20: Engine Vibration Symptoms

Possible Causes

Troubleshooting

Corrective Action

High vibes, gas generator (alarm) High vibes, power turbine (alarm)


Perform functional check per WP 410 00 SPAM

Repair or replace accelerometers as required per WP 111 00 SPAM

High vibes, gas generator (shutdown) High vibes, power turbine (shutdown)

Rotor imbalance

Using vibration measuring instrumentation with frequency-scanning type filter, determine predominant frequency. If frequency is same as gas generator (power turbine), problem is probably gas generator (power turbine) caused

Replace gas generator (power turbine) if vibes > alarm levels and no other cause is found

Engine not mounted securely

SPAM: Check all engine mount systems

SPAM: Realign and tighten mounts

Bearing failure

Check chip detectors for metal particles per WP 400 00 Check oil scavenge inlet screens for metal particles per WP 400 00

Repair or replace engine as required Repair or replace engine as required

FOD



Compressor or turbine damage

Inspect compressor inlet area per WP 401 00 Borescope engine per WP 406 00


Loose sensor/mounting

Inspect sensor mounting system

Repair sensor mount

High speed coupling shaft or driven load unbalance

SPAM



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-21: Temperature Sensors Symptoms T48 - Loss of average reading T48 - Cold sensor

Possible Causes Sensor or cabling failure, Type K thermocouple

T48 - Loss of three adjacent probes T48 - Loss of four probes T48 - Loss of any probe T48 - High or over limit T48 max - T48 min spread exceeds 200°F (93°C)

Signal-conditioning or display failure System ground loop

Sensor or cabling failure, Type K thermocouple Signal-conditioning or display failure System ground loop

Water, oil, or corrosion on electrical connector pins or sockets

Fuel nozzle condition

Troubleshooting Table 9-4 Table 9-5 SPAM SPAM

Corrective Action Repair or replace as required per WP 108 00 SPAM

Table 9-4 Table 9-5 SPAM Table 9-4 Table 9-5 SPAM SPAM

Repair or replace as required per WP 108 00 SPAM

Table 9-4 Table 9-5 SPAM Inspect for contaminants on electrical pins or sockets If no contaminants are found, proceed to fuel nozzle condition troubleshooting Identify highest and lowest reading T48 probes Identify fuel nozzle affecting the temperature of highest and lowest reading T48 probes (See Figure 9-1A) Mark locations of these fuel nozzles and remove for inspection per WP 101 00



Clean/replace as required


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-21: Temperature Sensors - (Cont.) Symptoms (Cont.) T48 max - T48 min spread exceeds 200°F (93°C)

Possible Causes (Cont.) Fuel nozzle condition

T3 sensor failure T3 A/B difference over limit

T2 sensor failure T2 A/B difference over limit

Sensor or cabling failure, Type K thermocouple Signal-conditioning or display failure Sensor or cabling failure, RTD, see Table 9-6

Lube supply or scavenge temperature sensor failure

Signal-conditioning or display failure Sensor or cabling failure, RTD, see Table 9-7

RTD A/B difference excessive

Signal-conditioning or display failure

Troubleshooting Inspect for clogging or burning If no clogging or burning is noted, swap positions of removed fuel nozzles by installing fuel nozzles from lowest reading probe upstream of highest reading probe and vice versa per WP 101 00 Operate engine and check effect of this change. Repeat previous steps as required Table 9-4 Table 9-5

Corrective Action Clean/replace as required


SPAM Table 9-4

Table 9-5


SPAM Table 9-4 Table 9-5 SPAM

Repair or replace as required per WP 110 00

TS-22: Speed Sensors Symptoms NGG sensor failure NGG sensor mismatch

NPT sensor failure NPT sensor mismatch

Possible Causes Sensor system failure

Signal-conditioning or display failure Same as above

Troubleshooting Check sensor resistance per Table 9-9 Check sensor gap per WP 105 00 Check sensor voltage per paragraph 9-2.1.2 SPAM

Corrective Action Repair or replace as required per WP 105 00

Same as above

Same as above



GEK 105054 Volume I

Troubleshooting Procedures - (Cont.) TS-23: Flame Sensor Symptoms Flame loss, one sensor (alarm) (no flameout) Flame loss, two sensor (shutdown)

Possible Causes Sight glass lens dirty Sensor lens dirty Sensor failure

Troubleshooting Inspect lenses

Corrective Action Clean or replace as required per WP 118 00

Verify operation with UV light source

Replace sensor as required per WP 118 00

Wiring

SPAM: Check package connections from sensor to package signal conditioner SPAM: Check system voltages Switch sensor inputs at amplifier to determine whether problem follows sensor

Repair or replace as required

Signal conditioner failure

SPAM

TS-3 TS-24: Miscellaneous Problems Symptoms Loss of performance

Possible Causes Compressor dirty High inlet filter pressure drop VSV system off- schedule FOD

High NGG rotor speeds at low power low T48

Normal deterioration due to normal operation, consistent with total operating time VSV system offschedule closed Compressor dirty FOD

High NGG, low power, high T48

Compressor dirty VSV system offschedule CDP bleed off-schedule

Troubleshooting Inspect inlet per WP 401 00 Borescope compressor per WP 406 00

Corrective Action Water-wash engine per WP 405 00

TS-18 Borescope engine per WP 406 00 Borescope engine per WP 406 00

Repair or replace engine as required Refurbish as required

TS-18 Borescope inspect compressor per WP 406 00 Borescope engine per WP 406 00 Inspect inlet per WP 401 00 Borescope compressor per WP 406 00

Repair or replace engine as required Water-wash engine per WP 405 00

TS-18 SPAM


GEK 105054 Volume I


Troubleshooting Procedures - (Cont.) TS-24: Miscellaneous Problems - (Cont.) Symptoms

Possible Causes

Low PT thrust balance cavity pressure (alarm)

Troubleshooting

Air supply leaks Worn PT balance piston seal

SPAM: Check for air leaks and verify accuracy of indication system

Corrective Action If no leaks or indication error, replace orifice plate per Volume II, WP 431 00

Table 9-1. LVDT/Torque Motor Resistance Values for TS-18 Component

Reference Figure

Interface

Component Pins

Resistance* (Ohms±10%)

Corrective Action

VSV Actuator Valve LVDT

9-1 (Sheet 6)

E40 Connectors 2 and 3

2-3 4-5 6-7

Primary Sec Y Sec Y

Replace VSV Actuator per

E46 E47

A-B

VSV Servovalve

9-1 (Sheet 7)

WP 100 00

Replace VSV Servovalve per WP 121 00

* At room temperature or as specified in tables. Table 9-2. Flame Detector Resistance Values Component

Reference Figure

Interface

Component Pins


Corrective Action

Flame Detectors

—

—

1-2

511

Replace flame detectors per WP 118 00

* At room temperature or as specified in tables. Table 9-3. Accelerometer Resistance Values Component

Reference Figure

Interface

Component Pins


Corrective Action

CRF/TRF Accelerometer with Integral Leads

9-1 (Sheet 8)

E13/E1

1-2 1-case 2-case

N/A 1.0 MΩ min 1.0 MΩ min

Replace accelerometer per WP 111 00

* At room temperature or as specified in tables.



GEK 105054 Volume I

Table 9-4. Temperature Sensor Resistance Values for TS-21 Sensor

Component

Reference Figure

Interface

Component Pins

Resistance* (Ohms)

T48 Type K Thermocouple (T/C)

Sensors

9-1 (Sheet 1)

T/C #1 T/C #2 T/C #3 T/C #4 T/C #5 T/C #6 T/C #7 T/C #8

KN-KP

0.44 to 0.83

—

Terminal to case

1.0 MΩ min

Measure both terminals to case

E21A/ E21B

1-1 2-2 3-3 4-4 5-5 6-6 7-7 8-8 Pin to shield

Continuity

May be measured at either end of the on-engine harness (at connector)

1-1 2-2 3-3 4-4 5-5 6-6 7-7 8-8

Continuity

On-engine harness

Off-engine cabling

T3 Type K T/C

9-1 (Sheet 1)

N/A

SPAM

Comments

1.0 MΩ min

Table 9-5 1.0 MΩ min

Sensor/ harness

9-1 (Sheet 3)

E30A/ E30B

A-B C-D Terminal to shield

2.1-2.6 2.1-2.6 1.0 MΩ min

Off-engine cabling

N/A

SPAM

A-A B-B C-C D-D

Table 9-5 Table 9-5 Table 9-5 Table 9-5

May be measured at either end of the on-engine harness (at connector)


GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 9-4. Temperature Sensor Resistance Values for TS-21 - (Continued)

Sensor

Component

Reference Figure

Interface

Component Pins

Resistance* (Ohms)

Comments

T2 RTD

Sensor

9-1 (Sheet 6)

E40

1-2 3-4

Table 9-6 Table 9-6

Standard and optional sensors each have two 100-ohm @ 32°F (0°C) RTDs in each probe. Each probe has an integral lead

On-engine cabling

9-1 (Sheet 6)

E40

Any lead 1-18 2-19 3-20

Continuity

May be measured at either end of the onengine harness (at connector)

Sensor

9-1 (Sheet 4)

E3C/E3D E4C/E4D E5C/E5D E18C/E18D E6C/E6D E11C/E11D

1-2 3-4

Table 9-7 Table 9-7

Sensors each have two 100-ohm @ 32°F (0°C) RTDs in each probe.

Off-engine cabling

N/A

SPAM

Any lead

Continuity

May be measured at either end of the onengine harness (at connector)

Lube RTDs

* At room temperature or as specified in tables.



GEK 105054 Volume I

Table 9-5. Cable Circuit Resistance Values At Room Temperature (or as specified in Tables) Cable Length (ft)

Table 9-7. Lube RTD Resistance Values Temperature

Resistance (Ohms)

Resistance

(°F)

(°C)

(Ohms ±10%)

-40.0

-40.0

84

1.1 - 1.8

0.0

-17.8

92

4.0 - 6.4

1.7 - 2.7

32.0

0.0

100

40

5.3 - 8.6

2.2 - 3.6

50.0

10.0

104

50

6.7 - 10.7

2.8 - 4.4

60

8.0 - 12.9

3.4 - 5.3

100.0

37.8

115

150.0

35.6

126

200.0

93.3

137

250.0

121.1

150

300.0

148.9

159

KP

KN

10

1.3 - 2.1

0.5 - 0.9

20

2.6 - 4.3

30

Table 9-6. T2 Resistance Values Temperature

Resistance

(°F)

(°C)

(Ohms ±10%)

-40

-40

84

0

-18

92

350.0

176.7

170

32

0

100

400.0

204.4

181

50

10

104

100

38

115

200

93

137 Table 9-8. Lube System Chip Detector

Component

Reference Figure

Chip Detector

9-1 (Sheet 5)

Interface E41 E42 E43 E44 E45

Component Pins

Resistance (Ohms)

Corrective Action

1-2

1.0 MΩ

Pin to case

> 1.0 MΩ

Low resistance indicates chip or short. Replace detector


GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 9-9. Speed Sensor Resistance Values

Component NGG

Reference Figure 9-1 (Sheet 2)

NPT

9-1 (Sheet 2)

Interface E7/E12

E14/E15

Component Pins

Resistance (Ohms ±10%)

1-2 1-2 Pin to case

200

A-B A-B Pin to case

80 (L21656P04) 950 (L44630P01) 1.0 MΩ

1.0 MΩ

Table 9-10. Maximum Allowable Instrumentation and Accessory Temperatures Components

Temperature

Lube Oil RTDs

220°F (104°C)

NGG Speed Sensor

225°F (107°C)

Variable Stator Vane Actuators

350°F (177°C)

Accelerometers

500°F (260°C)

T48 Sensor (At Lugs)

600°F (316°C)

T3 Sensor (At Connector)

600°F (316°C)

Lube Pump

300°F (149°C)

Starter

250°F (121°C)

UV Flame Detectors

200°F (93°C)

NPT Speed Sensor

600°F (316°C)



GEK 105054 Volume I

Figure 9-1. Electrical System Schematic Interface E21A and E21B (Sheet 1 of 8) 9-49 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I


Figure 9-1. Electrical System Schematic Interface E7, E12, E14, and E15 (Sheet 2 of 8) 9-50 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


GEK 105054 Volume I

Figure 9-1. Electrical System Schematic Interface E30A and E30B (Sheet 3 of 8)


GEK 105054 Volume I


Figure 9-1. Electrical System Schematic Interface E3C, E4C, E5C, E6C, E11C, and E18C (Sheet 4 of 8)



GEK 105054 Volume I

Figure 9-1. Electrical System Schematic Interface E41, E42, E43, E44, and E45 (Sheet 5 of 8) 9-53 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I


Figure 9-1. Electrical System Schematic Interface E40 (Sheet 6 of 8) 9-54 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


GEK 105054 Volume I

Figure 9-1. Electrical System Schematic Interface E46 and E47 (Sheet 7 of 8)

Figure 9-1. Electrical System Schematic Interface E1 and E13 (Sheet 8 of 8)


GEK 105054 Volume I


Figure 9-1A. Fuel Nozzle/T48 Probes Relationship 9-56 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


GEK 105054 Volume I

CHAPTER 10 General Maintenance Practices •

Left - the side opposite the right side

This chapter covers general maintenance practices and procedures to be followed during all maintenance operations.

•

Top - the side of the engine that is up when the engine is in the normal operating position

10-2

•

Bottom - the side of the engine on which the gearboxes are mounted

•

Clock Positions - the positions of the numbers on a clock face, as seen from aft looking forward. 12:00 o'clock is at the top, 3:00 o'clock is on the right side, 6:00 o'clock is at the bottom, and 9:00 o'clock is on the left side.

10-1

PURPOSE AND SCOPE

LEVELS OF MAINTENANCE

The workscope for level 1 corrective maintenance allows replacement of external parts, adjustments, and other work (preventive and corrective) up to and including removal and replacement of the entire engine. The workscope for level 2 corrective maintenance permits the replacement of major engine sections (modules) and the replacement or repair of certain internal parts. Level 2 maintenance is performed on-site on a noninstalled engine or on an installed engine in the enclosure, as permitted by the enclosure design. Maintenance is performed with the engine horizontal. See Volume II. 10-3

POINTS OF REFERENCE

10-4 STANDARD MAINTENANCE PRACTICES 10-4.1

WARNING

•

THE FOLLOWING STEPS MUST BE PERFORMED BEFORE ENTERING THE ENCLOSURE. THESE CONDITIONS MUST BE MAINTAINED WHILE INSIDE THE ENCLOSURE TO PREVENT INJURY TO PERSONNEL.

•

THE FIRE EXTINGUISHING SYSTEM MUST BE DEACTIVATED BEFORE PERSONNEL ENTER THE ENCLOSURE. SUFFOCATION CAN OCCUR IF THE FIRE EXTINGUISHING SYSTEM IS ACTIVATED.

The following points of reference are used throughout this manual: forward, aft, right, left, top, bottom, and clock position. These points of reference are defined as follows:

•

Forward - the air intake end of the engine

•

Aft - the exhaust end of the engine

•

Right - the right side of the engine, when viewed from the aft end and when the engine is in the normal operating position (gearbox down)

Safety

Observe all safety precautions listed below, as well as those listed in Chapter 1 and Chapter 7.


10-1

GEK 105054 Volume I


Wear protective clothing, gloves, safety glasses, etc., as required by the maintenance to be performed. Ensure that the engine will not be started while personnel are inside the enclosure. Post an observer at the exit, while maintenance is being performed inside the enclosure. WARNING

•

•

WHEN PERFORMING MAINTENANCE ON ELECTRICAL COMPONENTS, AVOID SHOCKS AND BURNS BY TURNING OFF ELECTRICAL POWER TO THOSE COMPONENTS, EXCEPT WHEN NECESSARY TO TAKE VOLTAGE MEASUREMENTS. TAG ELECTRICAL SWITCHES OUT OF SERVICE, TO PRECLUDE INADVERTENT ACTIVATION. TAG THE ENGINE OPERATING CONTROLS DO NOT OPERATE, TO PREVENT STARTING DURING A DESIRED SHUTDOWN CONDITION.

Turn off all electrical power, fuel, and air service to system on which maintenance is to be performed. Allow the engine to cool. Confirm that gas fuel lines have been vented/purged. The following steps must be performed upon exiting the enclosure after completion of maintenance: a.

Ensure that no personnel are inside the enclosure.

b.

Close the enclosure door.

10-2

c.

Turn on electrical power, fuel, and air services.

d.

Activate fire extinguisher system.

10-4.2

Tools and Tasks

All hardware items have been manufactured to English measurement units. Use of substitute metric sizes is not recommended and will void the warranty for interfacing parts. Tools in metric sizes should be furnished with suitable adapters to mate with English measurement unit sizes given. Limits, fits, and clearances may be interpreted in either English or metric units, as shown in the tables. NOTE Most of the tasks outlined can be done within the enclosure, if the horizontal maintenance option is selected, provided that tooling is available. Deviations from the procedures in the Volume II work packages are permitted, as necessary, to adapt to the needs dictated by the enclosure design, provided that these deviations do not compromise the intent of the instruction. Some modular change-outs may be done within the enclosure and some outside, whichever is more convenient. Consult the packager for planning assistance when questions arise. 10-4.3

Torque

In these maintenance procedures, all threaded parts on the engine will be tightened to a specific torque value. Special torque values, if required, will be stated in the text; otherwise, standard torque values should be used.



Torque values are expressed in lb in. (poundinches), lb ft. (pound-feet), or N•m (Newtonmeter). One pound-inch (or 1.0 pound-foot) is the twisting force of 1.0 pound applied to a twist-type fastener (such as a bolt or nut) with 1.0 inch (or 1.0 foot) of leverage. This twisting force is applied to the fastener to secure the components. N•m is the metric version of this applied force. It is important to use the correct torque wrench for the amount of torque being applied. See Table 10-1 for torque wrench ranges and requirements.

GEK 105054 Volume I

CAUTION IF TORQUE SHOULD INCREASE SIGNIFICANTLY PRIOR TO FINAL SEATING OF ANY THREADED FASTENER, REMOVE AND INSPECT THE FASTENER FOR THE CAUSE OF THE TORQUE INCREASE. Never over-torque any fastener. Torque limits are provided in the text and in Tables 10-2 through 10-5; these limits must be observed. Refer to paragraph 10-4.3.1 for application information. Do not use lubricant on bolt threads unless specified in assembly procedures. Start threads at least two turns by hand to ensure proper engagement.

Table 10-1. Torque Wrench Ranges and Requirements Torque Range

Torque Wrench Capacity

0 - 25 lb in.

(0 - 2.8 N•m)

0 - 30 lb in.

(0 - 3.4 N•m)

25 - 140 lb in.

(2.8 - 15.8 N•m)

0 - 150 lb in.

(0 - 16.8 N•m)

140 - 550 lb in.

(15.8 - 62.1 N•m)

0 - 600 lb in.

(0 - 67.2 N•m)

30 - 140 lb ft

(40.7 - 189.8 N•m)

0 - 150 lb ft

(0 - 203.4 N•m)

140 - 240 lb ft

(189.8 - 325.4 N•m)

0 - 250 lb ft

(0 - 339.0 N•m)

240 - 1000 lb ft

(325.4 - 1356.0 N•m)

0 - 1000 lb ft

(0 - 1356.0 N•m)


10-3

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 10-2. Torque Values for Steel Bolts, Nuts, and Self-Locking Nuts Torque Value

Size

Threads Per Inch

lb in.

N•m

8

32

13 - 16

1.5 - 1.8

10

24

20 - 25

2.3 - 2.8

1/4

20

40 - 60

4.5 - 6.8

5/16

18

70 - 110

7.9 - 12.4

3/8

16

160 - 210

18.1 - 23.7

7/16

14

250 - 320

28.2 - 36.2

1/2

13

420 - 510

47.5 - 57.6

8

36

16 - 19

1.8 - 2.1

10

32

33 - 37

3.7 - 4.2

1/4

28

55 - 70

6.2 - 7.9

5/16

24

100 - 130

11.3 - 14.7

3/8

24

190 - 230

21.5 - 26.0

7/16

20

300 - 360

33.9 - 40.7

1/2

20

480 - 570

54.2 - 64.4

10-4



GEK 105054 Volume I

Table 10-3. Torque Values for Engine Plugs and Unions Tube OD (inches)

Fitting Dash No.

Torque Value

1/8

2

40 - 50 lb in.

(4.5 - 5.6 N•m)

3/16

3

90 - 100 lb in.

(10.2 - 11.3 N•m)

1/4

4

135 - 155 lb in.

(15.3 - 17.5 N•m)

5/16

5

155 - 175 lb in.

(17.5 - 19.8 N•m)

3/8

6

180 - 200 lb in.

(20.3 - 22.6 N•m)

1/2

8

270 - 300 lb in.

(30.5 - 33.9 N•m)

5/8

10

360 - 400 lb in.

(40.7 - 45.2 N•m)

3/4

12

45 - 50 lb ft

(61.0 - 67.8 N•m)

1

16

58 - 70 lb ft

(78.6 - 94.9 N•m)

1-1/4

20

75 - 87 lb ft

(101.7 - 117.9 N•m)

1-1/2

24

83 - 100 lb ft

(112.5 - 135.6 N•m)


10-5

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 10-4. Torque Values for Tubing Nuts and Hose Fittings Hose Dash No. (Size)

Tube OD (Inches)

Aluminum Female Sealing Surfaces (See Note 1)

0.125

(1/8)

-2

–

0.1875

(3/16)

-3

30 - 50 lb in.

0.25

(1/4)

-4

0.3125

(5/16)

0.375

–

Steel Female Sealing Surfaces (See Note 2) 40 - 50 lb in.

(4.5 - 5.6 N•m)

(3.4 - 5.6 N•m)

90 - 100 lb in.

(10.2 - 11.3 N•m)

40 - 65 lb in.

(4.5 - 7.3 N•m)

135 - 155 lb in.

(15.3 - 17.5 N•m)

-5

60 - 80 lb in.

(6.8 - 9.0 N•m)

180 - 200 lb in.

(20.3 - 22.6 N•m)

(3/8)

-6

75 - 125 lb in.

(8.5 - 14.1 N•m)

270 - 300 lb in.

(30.5 - 33.9 N•m)

0.50

(1/2)

-8

150 - 200 lb in.

(16.9 - 22.6 N•m)

450 - 550 lb in.

(50.8 - 62.1 N•m)

0.625

(5/8)

-10

200 - 300 lb in.

(22.6 - 33.9 N•m)

650 - 770 lb in.

(73.4 - 87.0 N•m)

0.75

(3/4)

-12

25 - 35 lb ft

(33.9 - 48.0 N•m)

75 - 91 lb ft

(101.7 - 123.3 N•m)

1.0

(1)

-16

41 - 58 lb ft

(55.6 - 78.6 N•m)

112 - 128 lb ft

(151.8 - 173.5 N•m)

1.25

(1-1/4)

-20

50 - 75 lb ft

(67.8 - 101.7 N•m)

133 - 150 lb ft

(180.3 - 203.4 N•m)

1.5

(1-1/2)

-24

50 - 75 lb ft

(67.8 - 101.7 N•m)

158 - 183 lb ft

(214.2 - 248.1 N•m)

NOTES:

10-6

1.

These values apply when female sealing surface is aluminum. Male connector and nut may be either steel or aluminum.

2.

These values apply when female sealing surface is steel. Male connector and nut may be either aluminum or steel.



GEK 105054 Volume I

Table 10-5. Torque Values for Plugs and Unions Used in Bosses and for Universal Bulkhead Fitting Locknuts Torque Dash No. (Size)

Threads Per Inch

Size

lb in.

lb ft

N•m

2

0.3125

24

40 - 50

5.2 - 5.6

3

0.375

24

90 - 100

10.2 - 11.3

4

0.4375

20

135 - 155

15.3 - 17.5

5

0.50

20

155 - 175

17.5 - 19.8

6

0.5625

18

180 - 200

20.3 - 22.6

8

0.750

16

270 - 300

30.5 - 33.9

10

0.875

14

360 - 400

40.7 - 45.2

12

1.0625

12

540 - 600

45 - 50

61.0 - 67.8

16

1.3125

12

700 - 850

58 - 70

78.6 - 94.9

20

1.635

12

900 - 1050

75 - 87

101.7 - 117.9

24

1.875

12

1000 - 1200

83 - 100

112.5 - 135.6

10-4.3.1

Standard Torque

Use the following standard torque tables, unless otherwise directed in the text. Use the torque values given in Table 10-2 for steel bolts and nuts (including self-locking nuts). Values given are for clean bolts and nuts that are free of nicks and burrs. Use half the value given in Table 10-2 for the following applications:

•

Thin steel hex nuts

•

Non-steel nuts and bolts, except titanium.

•

All bolts threaded directly into aluminum, magnesium, or other non-steel parts.

Use the torque values given in Tables 10-3 and 10-4 for gasketed fittings. Install fittings as instructed in paragraph 10-4.6. Torque values given in Tables 10-3 and 10-4 are for packing made of synthetic material, asbestos compounds, or soft metal (copper, aluminum, etc.). These values do not apply to steel gaskets or special boss seals.


10-7

GEK 105054 Volume I 10-4.3.2


Running Torque

10-4.3.3

Refer to Table 10-6 for minimum running torque on self-locking nuts. This table applies to silver-plated, lubricated, and nonlubricated self-locking nuts. Values given are for nuts with no axial load. To check minimum running torque, screw the nut onto a bolt until two to five threads are exposed beyond the nut. Measure the amount of torque required to turn the nut on or off the bolt. Nuts that do not meet these minimum frictional requirements should be replaced.

Tightening Procedures CAUTION

WHEN CHILLING OR HEATING AN ENGINE PART DURING ASSEMBLY, DO NOT TORQUE SPANNER NUTS, LOCKNUTS, OR RETAINING BOLTS UNTIL THE PART HAS RETURNED TO ROOM TEMPERATURE. THE FASTENER MAY LOOSEN AS THE PART COOLS OR MAY BE OVERSTRESSED AS THE PART WARMS AND EXPANDS. If possible, tighten at a uniformly increasing rate until the desired torque is obtained. In cases where gaskets or other parts cause a slow permanent set, be sure to hold the torque at the desired value until the material is seated.

Table 10-6. Minimum Running Torque for Self-Locking Nuts Minimum Running Torque Threads/ Inch

Size

lb in.

N•m

0.136 (6)

32/40

1.0

0.11

0.164 (8)

32/36

1.5

0.16

0.190 (10)

32

2.0

0.22

1/4

28

3.5

0.39

5/16

24

6.5

0.73

3/8

24

9.5

1.07

7/16

20

14

1.6

1/2

20

18

2.0

9/16

18

24

2.7

5/8

18

32

3.6

3/4

16

50

5.6

10-8



CAUTION TORQUE SHALL BE LESS THAN THE FINAL TORQUE REQUIRED FOR THE SMALLEST DIAMETER BOLT. THIS PREVENTS SHEARING OR BREAKING OF TIGHT BOLTS DUE TO FORCE CONCENTRATIONS. Apply uniform torque to a series of bolts that have different diameters, and are installed on one flange or in one area. CAUTION IT IS NOT DESIRABLE TO TIGHTEN TO THE FINAL TORQUE VALUE DURING THE FIRST DRAWDOWN; UNEVEN TENSION CAN CAUSE DISTORTION OR OVERSTRESSING OF PARTS.

GEK 105054 Volume I

Torque mating parts by tightening the bolts or nuts gradually, until the parts are firmly seated. Loosen each fastener by one-quarter turn, then apply final tightening. Tightening in a diametrically opposite (staggered) sequence is desirable in most cases (Figure 10-1). Do not exceed listed maximum torque values. All bolts are installed with heads forward and up with nuts aft and down, unless otherwise specified. Washers are installed beneath the part that turns when tightening, unless otherwise specified. The torque wrenches listed in Table 10-1 are recommended for use within the indicated ranges. Larger wrenches have too great a tolerance and can result in inaccuracies.

Figure 10-1. Tightening Sequence for Threaded fasteners Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

10-9

GEK 105054 Volume I


Torque values specified in this manual are actual values to be applied to fasteners. Whenever an adapter (crowfoot, spanner wrench, etc.) is used with a torque wrench, torque must be calculated per Figure 10-2. Inspect all nuts and bolts after tightening to make sure they are seated. If any nut or bolt is not seated after the required torque has been applied, remove and inspect for thread damage. Lubricate tube/hose connector threads and between the B-nut and ferrule of a connector. Run B-nuts onto fittings by hand to ensure that tubes and hoses are aligned and threads are free of burrs. Two wrenches must be used when loosening or tightening B-nuts, one on the fitting to which the tube or hose is being connected to hold it stationary and one on the B-nut for torquing. This not only prevents twisting the tube, but also prevents loosening or over-tightening the fitting. When using an extension on a torque wrench, calculate the correct torque input before applying torque per Figure 10-2. 10-4.4

Loose Fasteners

Prior to retightening, examine the fastener and the joint for the cause of the looseness. If safety wire or fastener is broken, ensure root cause for fastener/joint looseness is resolved before retightening. If safety wire is missing, tighten to the required torque and safety-wire the fastener. If the fastener has a self-locking feature, check breakaway torque per the preceding step. Replace defective fasteners as required.

10-10

10-4.5

Tri-Wing/Torx Fasteners

Tri-wing/torx recessed-head fasteners are available in a wide range of sizes and each size requires the use of a matched driver. See Figure 10-3. When properly used, the tri-wing/torx design permits a higher ratio of torque to end-pressure than is possible with slotted-head or cross-head designs, minimizing burring and mutilation. The following procedures should be used for tri-wing/torx fasteners: 10-4.5.1

Installation

Select the correct driver. The driver number should match the recess number of the fastener head as shown in Figure 10-3. Table10-7 lists a range of standard fastener sizes with their corresponding tri-wing/torx recess identification numbers. Table 10-7. Tri-Wing/Torx Drivers and Standard-Thread Fasteners Screw Thread Size

Tension Head

Shear Head

0 - 80

0

–

2 - 56

1

–

4 - 40

2

1

6 - 32

3

2

8 - 32

4

3

10 - 32

5

4

1/4 - 28

6

5

5/16 - 24

7

6

3/8 - 24

8

7

7/16 - 20

9

8

1/2 - 20

10

9

9/16 - 18

11

10

5/8 - 18

12

11

3/4 - 16

13

12

7/8 - 14

14

13

1 - 12

15

14



GEK 105054 Volume I

Figure 10-2. Torque Wrench Correction Factor Determination Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

10-11

GEK 105054 Volume I


Figure 10-3. Tri-Wing/Torx Fastener Drive Be sure that the axis of the drive is aligned with the axis of the fastener when installing or removing the fastener. If the head of the fastener has been coated with paint or other material, use a driver one size smaller than that indicated, to compensate for the thickness of material on the walls of the recess. 10-4.5.2 Extraction There is no slope to the walls of mating surfaces of either fastener or driver, so that the tendency of the driver to slip out of the recess is minimized. Normal extraction by applying counterclockwise (CCW) torque is usually successful. If corrosion or other factors have caused the fastener to seize so that failure of the recess occurs, select the proper drill and screw extractor for the size of fastener involved. The bottom of the fastener recess is shaped so that the drill centers itself naturally and no special drilling procedure is required. Drill into the fastener 10-12

deep enough to provide sufficient working depth for the screw extractor. Tap the extractor to seat it firmly, then apply CCW torque to remove the fastener. 10-4.6 Universal Fittings Universal fittings should be installed according to the procedures described below. 10-4.6.1 Nonpositioning Fittings (See Figure 10-4.) a.

Lubricate preformed packing and roll it over the threads into the groove in the fitting.

b.

Screw the fitting into the boss until preformed packing contacts the surface of the boss.

c.

Tighten the fitting to the proper torque value.



GEK 105054 Volume I

Figure 10-4. Nonpositioning Fittings 10-4.6.2 Positioning Fittings (See Figure 10-5.) a.

Screw the jamnut completely over the first section of threads on the fitting, past the packing groove, and onto the second section of threads.

b.

Lubricate preformed packing and roll it over the threads into the groove in the fitting.

c.

Turn jamnut until it just bears against preformed packing.

d.

Screw the fitting into the boss until preformed packing contacts the surface of the boss.

e.

Turn fitting to desired position by backing out not more than one turn.

f.

Attach the line to the fitting and check the alignment of the fitting.

g.

Hold the fitting and tighten the nut to the proper torque.

10-4.6.3 Bulkhead Fittings (See Figure 10-6.) a.

Attach bulkhead fitting to bulkhead with jamnut as shown in Figure 10-6.

b.

Connect tube or hose nut and tighten.

c.

Hold fitting with wrench and tighten jamnut to the specified torque value.


10-13

GEK 105054 Volume I


Figure 10-5. Positioning Fittings 10-14



GEK 105054 Volume I

Figure 10-6. Bulkhead Fittings 10-4.7 Gaskets, Preformed Packings, and Expendable Parts Gaskets, preformed packings, key washers, and cotter pins shall not be reused, unless otherwise specified. Gaskets and preformed packings shall be lightly lubricated with engine lube oil prior to installation, unless otherwise specified. Ensure parts are properly seated. When a fitting with a jamnut and preformed packing is used, see Figures 10-4 and 10-5 for the proper installation procedure. See Figure 10-7 for preformed packing used with flexible sleeve type fittings.

10-4.8

Tubes

When installing tubes, the following precautions and instructions apply.

•

Apply engine lube oil between the tube nut and the ferrule, prior to tightening (see Figure 10-8). As tubes are installed, tighten all end fittings and clamps fingertight. After a complete system is installed, torque clamps first and then end-fittings.

•

Maintain a minimum clearance of 0.125 inch (3.18 mm) between tubes and adjacent parts.

•

Tubes and manifolds must fit within 0.063 inch (1.60 mm) radius in a free state during assembly, or be replaced.

•

Coupling nuts shall thread freely by hand.


10-15

GEK 105054 Volume I


Figure 10-7. Flexible Coupling Assembly 10-16



GEK 105054 Volume I

Figure 10-8. Rigid Tube

•

Mating flanges on tubes shall seal flush within 0.005 inch (0.13 mm).

•

The distance between faces of mating surfaces or flanges shall not exceed 0.063 inch (1.60 mm).

•

Bend tubes in existing straight sections, if possible.

•

Use bending tools on any tube 1.0 inch (25.4 mm) or more in diameter, to prevent the tube from collapsing. WARNING VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELLVENTILATED AREA.

•

On those couplings where sealant is required, carefully apply a thin coat of sealant to each face of gasket and coupling mating surfaces. Wipe off any sealant on inside of tube with a clean rag and water. Do not allow sealant to enter air systems.

10-4.9

Hoses

(See Figure 10-9.) No hose should be bent more than the bend radius specified in Table 10-8, because of possible damage to Teflon liners. Before installing hoses, visually inspect the hose interior to assure that the Teflon lining has not been damaged. If damaged, replace the hose. Kinked hoses must not be used. Preformed hoses or hoses of large diameter shall not be bent or straightened (see Figure 10-10). During installation, be sure that no hose is twisted or stretched. Never over-torque connectors. When hoses are removed, cap the open ends.


10-17

GEK 105054 Volume I


Figure 10-9. Installation of Hose Assemblies 10-18



Table 10-8. Hose Minimum-Bend Radii Minimum-Bend Radius Dash Size

in

mm

3

1.5

38.10

4

2.0

50.80

5

2.0

50.80

6

4.0

101.60

8

4.62

117.348

10

5.5

139.70

12

6.5

165.10

16

7.38

187.452

20

11

279.4

24

14

356.6

32

22

558.8

GEK 105054 Volume I

Natural gas fuel hoses and fuel nozzle steam hoses have different and more restrictive requirements. Refer to the appropriate work package in Volume II for details. Fluid fittings shall be tightened gradually to the required torque value, backed off one-quarter turn, and then tightened again. Do not attempt to correct leaks by excessive tightening. Always use two wrenches when tightening swivel coupling nuts on hoses, tubes, or fittings. Hold the stationary part with one wrench while applying torque with second wrench.

Figure 10-10. Factory Preformed Hoses


10-19

GEK 105054 Volume I 10-4.10


Correction of Leaks CAUTION

DO NOT OVER-TORQUE THREADED FASTENERS AS A METHOD OF CORRECTING LEAKING CONNECTIONS. OVER-TORQUING COULD RESULT IN PART FAILURE. a.

Disassemble the connection.

b.

Discard the seal, gasket, or preformed packing, if present.

c.

Inspect mating surfaces for contamination, scratches, dents, or other surface defects.

d.

e.

Inspect threaded fasteners for thread damage and ensure that fasteners seat properly when tightened to specified values. Replace nonserviceable parts and assemble the connection, using new seals, gaskets, or preformed packings as required.

10-4.11

Clamps

Chafing of hoses and tubes must be avoided. Clamp parts loosely in place, shift the hoses until the best clearance is obtained, and then tighten the clamps (Figure 10-11). Clamps must be of the proper size for the piping to permit slippage during engine thermal growth. The cushion clamp liner position should also be checked before tightening the clamp (Figure 10-12). Clamps must be positioned over the wear sleeves on the tube.

10-20

10-4.12 10-4.12.1

V-Band (Coupling) Clamps Preinstallation Checks

Check alignment of tube ends, unrestrained, to the following maximum limits prior to installing V-band clamps:

•

Parallelism: no angle (centerlines of tubes or fittings parallel)

•

Offset between fittings or tube centerlines: no more than 0.06 inch (1.524 mm) circumferential, axial, or combined

•

Gaps: no more than 0.06 inch (1.524 mm) space between fitting seats

If tube ends do not align within the above limits, readjust mounting until proper alignment is attained. Check that flange faces are free of dirt, grease, corrosion, distortion, deformation, and scratches. Use protective flange caps on the ends of all ducts until the installation progresses to the point where removal of the cap is essential to continuing with the installation. Use care during the installation of ducts and tubes to ensure mating and alignment of flanges. A poorly fitted joint requires excessive torque on the T-bolt to close the joint and imposes structural loads on the V-band clamp. Adjacent support clamps or brackets should remain loose until installation of the coupling has been completed. When connections are by V-band couplings, the weight of the components should be fully supported during the fitup and installation of the couplings.



GEK 105054 Volume I

Figure 10-11. Routing and Clamping Techniques

Figure 10-12. Installation of Cushion Clamps


10-21

GEK 105054 Volume I


When reinstalling a used coupling, check it for twist or distortion. Visually check the V-section for spreading at the open ends or other signs of distortion. Check spot welds or rivets for condition and security. The corner radii should be carefully checked for tool marks and cracks. V-band couplings in poor condition should be replaced.

CAUTION

Check the threads on the T-bolt for wear and condition. If there is any sign of wear, galling, or deformation, install a new T-bolt or coupling clamp. Check the T-bolt for straightness; however, if it is bent, it will be necessary to determine if the bend is intentional. Some small diameter couplings have curved T-bolts. Check the applicable illustrated parts breakdown for part identification. If in doubt, install a new T-bolt or coupling clamp.

•

DO NOT USE PLIERS ON V-BAND CLAMPS TO FORCE ALIGNMENT OF TUBE ENDS WHILE ENGAGING V-BAND BOLTS AND NUTS. RESIDUAL STRESS IN THE TUBES AND NICKS, SCRATCHES, OR DEFORMATION IN THE CLAMPS, CAN CAUSE PREMATURE FAILURE OF THESE PARTS.

•

DO NOT SUBSTITUTE ANY OTHER COUPLING NUT FOR THE TYPE NUT SUPPLIED WITH THE COUPLING. THE CORRECT NUT (ESNA Z1200J SERIES) IS IDENTIFIED BY THE LETTER J STAMPED ON A WRENCH FLAT. FAILURE TO COMPLY MAY RESULT IN DUCT JOINT FAILURE.

Check the trunnion and latch for freedom of movement or other overloading.

a.

Place the V-band clamp over one of the tube ends far enough to clear the flange.

Avoid twisting, spreading, or bending of the coupling when positioning the coupling on the joint.

b.

Install the gasket, if required, and mate both flanges.

When gaskets are used in the joint, exercise care in handling to avoid nicks and burrs on the gasket surfaces. Whenever a joint is disassembled after service operations, a new gasket should be used when reassembling to ensure maximum sealing efficiency. Exercise care to ensure that the gasket is properly seated.

c.

Relocate the clamp over both flanges and press the clamp closed.

d.

Install the nut, check to ensure that the T-bolt is properly seated, and tighten the nut to approximately one-half of the required torque marked on the strap.

10-4.12.2

e.

Tap the clamp lightly around the circumference with a rubber mallet to equally distribute the load.

f.

Alternate tightening and tapping until torque stabilizes at the specified value. Avoid over-torquing.

g.

Inspect the clamp for even seating.

h.

See Figure 10-13 for safety-wiring the V-band clamp. Use 0.032 inch (0.81 mm) safety wire.

Installation

The following procedures should be followed to ensure proper V-band clamp installation:

10-22



GEK 105054 Volume I

Figure 10-13. V-Band Clamps and Safety-Wiring Techniques 10-4.13

INSTALLED SEAL COULD AFFECT THE USEFULNESS OF THE SEAL AND/OR CONNECTOR.

Electrical Cables and Connectors

During electrical cable installation, adjust the cable through the clamps to get the smoothest and largest radius. Sharp bends, twists, and kinks must be avoided. Minimum clearance between the electrical cable and any component other than hoses or other electrical cables is 0.125 inch (3.18 mm).

c.

CAUTION

Some connectors have a seal ring located in the coupling nut (Figure 10-14), if so, inspect to make sure the seal is present and serviceable before attaching the connector. Replace unserviceable seals as follows: a.

Remove the unserviceable seal.

b.

Engage the new seal over the barrel of the connector CAUTION DO NOT ALLOW THE SEAL TO TIP AND FLATTEN. AN INCORRECTLY

Push the seal to its seated position against the internal shoulder in the connector using a mating connector or blunt screwdriver.

DO NOT FORCE THE CONNECTORS TOGETHER. IF THE PINS ARE NOT ALIGNED, THEY WILL BE BENT OR DISTORTED AND WILL NOT MAKE CONTACT. d.

Electrical connectors on flexible harnesses and leads shall be hand-tightened beyond finger-tight (20 degrees maximum) until connecting parts are in solid contact without damage. Safety-wire the connectors only when specified in the procedure.


10-23

GEK 105054 Volume I


Figure 10-14. Electrical Connectors (Typical) e.

f.

If the connector is a locking connector, engage the connector and wiggle the backshell while tightening the coupling ring hand-tight. A clicking sound is produced during tightening of the connector. Ensure that the full coupling color band on the receptacle is not visible and that the backshell has no movement. Do not sharply bend, kink, or twist rigid leads. When tightening the connection, always hold both mating connectors to prevent damage to the leads.

10-24

10-4.14

Electrical Bonding Straps

Electrical bonding strap contact surfaces shall be prepared by removing all anodic film, grease, paint, lacquer, or other high-resistance material from an area at least one and one-half times the bonding surface contact area. Bonds shall be installed and contact surfaces sealed within 4 hours of cleaning. The area shall then be painted to match the surrounding area. NOTE The LM2500+ SAC package provides an interface (E16 and E17) for bonding lugs located at the power turbine mount bolts.



10-4.15

Safety Wiring

Safety wiring is the securing of two or more parts with a wire installed in such a manner that any tendency for a part to loosen will be counteracted by additional tightening of the wire. This is not a means for obtaining or maintaining torque, but rather a safety device used to prevent the disengagement of parts. See Figure 10-15 for general safety-wiring practices.

GEK 105054 Volume I

•

Safety wire shall not be installed in a manner to cause the wire to be subjected to chafing, fatigue through vibration, or additional tension, other than the tension imposed on the wire to prevent loosening.

•

Both 0.020 inch (0.51 mm) and 0.032 inch (0.81 mm) safety wires are used throughout the engine. The application is determined by the size of the hole in the unit to be safety-wired. Whenever possible, use the 0.032 inch (0.813 mm) safety wire. Only new safety wire shall be used in each application.

•

The safety wire shall be pulled taut while being twisted, and shall have nine to 12 twists per inch (25 mm) for 0.020 inch (0.51 mm) diameter wire and seven to 10 twists per inch (25 mm) for 0.032 inch (0.81 mm) diameter wire.

•

Hose and electrical coupling nuts shall be safety-wired in the same manner as tube coupling nuts.

•

Caution must be exercised while twisting to keep the wire tight without overstressing it or allowing it to become nicked, kinked, or otherwise mutilated. Only existing safety wire should be replaced; do not add safety wire which was not previously in place or specified in text.

•

When removing safety wire, identify safety-wiring holes on parts.

NOTE

•

•

Although not every possible combination of safety wiring is shown in Figure 10-15, all safety wiring must, in general, correspond to the examples shown. General Electric (GE) gas turbines use special locking cables at some locations. When removed for maintenance, these should be replaced with equivalent cables or safety wire using standard safety-wiring procedures in this chapter.

10-4.15.1 Safety Wiring General Practices The following rules for safety wiring shall be observed, unless specific instructions to the contrary are given in the text:

•

Safety wire shall consist of two strands of wire twisted together (so-called doubletwist method), where one twist is defined as being produced by twisting the strands through an arc of 180×, equivalent to half a complete turn. Use the single-strand method only when specified.


10-25

GEK 105054 Volume I


Figure 10-15. Safety-Wiring Practices (Sheet 1 of 2) 10-26



GEK 105054 Volume I

Figure 10-15. Safety-Wiring Practices (Sheet 2 of 2) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

10-27

GEK 105054 Volume I 10-4.15.2

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Safety Wire Installation

NOTE Apply light finger pressure at the midpoint of the safety wire span, and flex the wire in both directions to check for tautness.

The following safety-wiring procedures are to be used throughout the engine: CAUTION SAFETY WIRE SHOULD BE APPLIED SO THAT TENSION IS IN THE TIGHTENING DIRECTION, SO THAT ANY TENDENCY FOR A PART TO LOOSEN WILL BE COUNTERACTED BY THE SAFETY WIRE. FAILURE TO DO SO COULD RESULT IN PARTS COMING APART. a.

b.

c.

d.

Insert the safety wire through the first part and bend the upper end either over the head of the part or around it. If bent around it, the direction of wrap and twist of the strands shall be such that the loop around the part comes under the strand protruding from the hole. Done this way, the loop will not tend to slip upward and become slack. Twist the strands while taut until the twisted portion is just short of the nearest hole in the next part. The twisted portion should be within 1/8 inch (3.2 mm) of the hole in each part. If the free strand is to be bent around the head of the second part, insert the upper strand through the hole in this part, then repeat the previous step. If the free strand is to be bent over the unit, the direction of twist is unimportant. If there are more than two units in the series, repeat the preceding steps. After wiring the last part, continue twisting the wire to form a pigtail of three to eight twists (1/4 - 1/2 inch [6 - 13 mm] long) and cut off the excess wire. Bend the pigtail inward toward the part in such a manner as to prevent it from becoming a hazard to personnel.

10-28

e.

If the safety wire is not taut after safetywiring per the preceding instructions, use the limits shown in Table 10-9 to determine its acceptability. Table 10-9. Installed Safety Wire Flex Limit

Length of Safety Wire Between Parts

Total Flexing at Center

in

mm

in

mm

1/2

12.7

1/8

3.2

1.0

25.4

1/4

6.4

2.0

50.8

3/8

9.5

3.0

76.2

1/2

12.7

4.0

101.6

3/4

19.1

5.0

127.0

3/4

19.1

6.0

152.4

3/4

19.1

f.

If the safety wire fails to meet the limits shown in Table 10-9, remove it and install new safety wire.

Always cut, rather than break, safety wire so that safety-wire holes are not torn or pulled out. Instructions for dismantling and disassembly do not include safety-wire removal because of the obvious necessity for removing safety wire.



WARNING

GEK 105054 Volume I

•

The hand operated crimping tool operates in one direction only and has a cycle end dead stop to tell the operator when the ferrule is fully crimped. The crimping pressure of the tool is set by the manufacturer. If necessary, the crimping pressure can be adjusted with standard hand tools. The Snap-On tool has a spring loaded crimp rod to hold the ferrule in place during the crimping procedure. Cable tension is done automatically by the internal retraction mechanism.

•

Where possible, install the safety cable so it does not touch other parts.

•

Make sure the cable is not damaged or bent when installing safety cable through the holes in the fastener or part. Frayed cable assemblies are not permitted.

•

Install the safety cable through existing holes only.

•

Unless specified differently in the packager’s manual:

USE EXTREME CAUTION IN MONITORING THE SAFE AND COMPLETE REMOVAL OF ALL EXCESS SAFETY WIRE. CARE MUST BE TAKEN WHEN CUTTING OFF THE ENDS OF INSTALLED WIRE TO ENSURE COMPLETE RETRIEVAL IN ORDER TO PREVENT INJURY TO PERSONNEL AND/OR SUBSEQUENT ENGINE DAMAGE. When removing safety wire, ensure that all pieces are removed to prevent them from entering engine parts or otherwise causing damage. 10-4.16

Safety Cable

Safety cable is an alternative to safety wire. Safety cable is installed through two or more parts in such a way that as the fastener or part loosens the safety cable will tighten. When the safety cable tightens, it will not permit the fastener to part or turn. 10-4.16.1

Safety Cable General Practices

The safety cable system has three components: safety cable, ferrules and crimping tool.

•

•

The safety cable is available in one size, 0.032 inch (0.81 mm). One end of the cable will have a cable end fitting swaged to it. The strands of the cable on the opposite end of the cable are fused together to prevent the cable from fraying.

The maximum length of the safety cable between safety cabled parts is 6.0 inches (152.4 mm). No more than three bolts can be safetied with one safety cable. Safety cable shall not be used on titanium fasteners.

The ferrules are in a spring-loaded, disposable magazine. When the safety cable is installed the ferrule will be crimped on the open end of the cable.


10-29

GEK 105054 Volume I 10-4.16.2

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Crimping Tool Verification

e.

Perform a pulloff load test as often as necessary to make sure the crimp done by the crimping tool meets the necessary requirements. GE Aircraft Engines recommends the pulloff load test be done at the beginning, middle, and end of each shift. Refer to manufacturer's instructions for pulloff load test procedure. 10-4.16.3 a.

Safety Cable Installation

CAUTION

Perform a visual inspection of the holes to be safety cabled to find all damage. If the hole is damaged, replace the part or, if possible, use another hole to safety cable.

DO NOT PUT TOO MUCH TENSION ON THE SAFETY CABLE. THE CRIMPING TOOL WILL AUTOMATICALLY SET THE TENSION. TOO MUCH TENSION WILL BREAK THE SAFETY CABLE.

NOTE Keep the safety cable as straight as possible when you safety cable the fasteners or parts together. b.

Put the end of the cable without the cable end fitting into the hole in the part. Pull the cable through the hole until the cable end fitting is against the part.

c.

Insert the end of the cable through the second part. Choose the hole in the part that permits the cable to be as straight as possible. Pull the cable through the second part. If three parts must be safety cabled, perform the same procedure for the third part.

f.

Pull the safety cable to the tension post on the crimping tool. Wrap the cable completely around the post. Make sure the cable is in the groove at the top of the post. Pull the cable toward the drive handle until the cable goes behind the locking ball.

g.

Hold the crimping tool perpendicular to the cable in the bolt head. Ensure the ferrule is tightly against the bolt head. Lightly pull on the end of the safety cable to remove slack.

h.

Push the start cycle button and turn the drive handle clockwise. At the start of the cycle, the tension block will move backwards. This movement backwards provides the cable tension. When the drive handle is turned, release the start cycle button. Turn the drive handle until it stops (approximately two full turns).

i.

Pull up on the safety cable end to remove it from the tension block.

NOTE On a two bolt pattern, do not cable in a negative pull direction. Make sure the cable has a positive or neutral pull. d.

Put the end of the safety cable coming out of the last part to be safety cabled through a ferrule in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine.

10-30

Put the end of the safety cable through the crimping head of the crimping tool. Make sure the large hole in the crimping head is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the ferrule. Pull back on the retraction knob. Put the ferrule in the crimping head and release the retraction knob. Make sure the ferrule is fully in the crimping head.



j.

GEK 105054 Volume I

Pull back on the retraction knob and remove the crimping tool from the crimped ferrule and the remaining safety cable.

k.

Cut the unused safety cable even with the crimped ferrule. Use the side cushioned cutters. Discard the unused safety cable.

l.

Visually inspect safety cable for kinks, frayed wires, or improper crimps. Remove and replace safety cable if a problem exists.

m. Push against the safety cable with light finger pressure halfway between the safety cabled parts. If the cable feels loose, perform a dimensional check to ensure the safety cable is serviceable as follows (see Figure 10-16): (l)

(2)

(3)

Measure the distance between the safety cabled parts. Write this measurement down as Dimension A. If three parts are safety cabled together, measure the distance between each of the parts and add the two measurements together to get Dimension A. Push against the safety cable with light finger pressure halfway between two safety cabled parts. Measure the distance the safety cable moves laterally. Write this measurement down as Dimension C. Compare the dimensions that were written down to the limits given in Figure 10-16.

CAUTION DO NOT TRY TO BREAK THE SAFETY CABLE. IF THE SAFETY CABLE MUST BE REMOVED, CUT THE SAFETY CABLE TO AVOID DAMAGE TO THE HOLES IN THE PARTS. n.

If the safety cable is not in the limits given in Figure 10-16, cut the safety cable with wire cutters and remove the installed safety cable. Install new safety cable.

10-4.17

Jackscrews

When using jackscrews to remove components, do not bend flanges or strip threads. Lubricate jackscrews with engine lube oil before installing. Turn jackscrews inward evenly and in small increments. Always check for and remove burrs or rough edges before using jackscrews. If regular bolts are used as jackscrews, the tips must be blunt and polished. Do not allow components to fall free as jackscrews are tightened. Jackscrew holes are often in flanges that are only thick enough for three or four threads. The ends of most standard bolts are chamfered, and the first couple of threads are missing or incomplete. These should not be used as jackscrews without modification, since only one or two threads will engage and the threads in the flange are likely to strip. Jackscrews, frequently designed as special tools and identified as such, are not chamfered and full thread engagement will occur. If specially manufactured jackscrews are not available and must be manufactured locally, be sure that the ends are ground to remove the chamfer and the incomplete thread so that the maximum number of threads may be engaged.


10-31

GEK 105054 Volume I


Figure 10-16. Safety Cable Flex Limits 10-32



10-4.18

Protective Closures and Caps

Preventing foreign material from lodging in drilled passages, fuel lines, oil lines, air lines, and open engine ports is extremely important. Machined surfaces must be properly protected to prevent damage. Do not remove plugs, caps, etc., until the part is ready for assembly. Check both seating surfaces for removal of plugs, etc. prior to assembly. Wrap precision parts and cap, or plug, all openings and connections. It is most important that all engine parts be kept clean and free of corrosion. All instructions that specify special handling of parts must be followed without exception. Accessories, tubes, and hoses may contain fuel or oil at the time of removal. Drain these fluids from the accessory being removed and cap all connecting hoses or tubes. 10-4.19

GEK 105054 Volume I

Hands and gloves must be clean when handling machined surfaces. After performing any maintenance, the work area shall be thoroughly inspected for loose parts, rags, tools, and other materials. The area shall be cleaned to remove grit, dust, chips, safety wire, and other small objects. 10-4.20

The following general instructions apply during unpacking and repacking to minimize possible part damage and contamination.

•

Initially, remove only that portion of the packing material necessary to mount the part. Where possible, remove the remainder of the packing material, including protective caps and plugs, one at a time as each connection (fluid, air, or electrical) is made.

•

Retain protective caps and plugs and reusable packing components for repacking purposes.

•

Install a cap or plug on each connection (fluid, air, or electrical) as it is disconnected.

•

When possible, repack the part for storage or shipment, using the same packing material in which the replacement part was received.

•

When original packing components are not available, use locally available packing materials and containers to pack the part. Make sure all ports, openings, connections, and mating surfaces are capped or covered and that the part is protected from potential handling or environmental damage.

•

Bearings shall be handled per paragraph 10-4.21 in this chapter.

Cleanliness

Cleanliness is important for equipment life and proper operation. One of the major causes of premature engine removal is foreign object damage (FOD). The enclosure must be kept clean and free of dirt and loose objects. It is recommended that small containers for foreign objects be kept in the work area or in tool boxes. All parts shall be inspected for cleanliness before being installed. Gaskets and preformed packings shall be free from dirt, lint, and/or grit. Mating flanges, tube flanges, and couplings shall be wiped clean to make sure that a good seal will be obtained.

Unpacking and Repacking


10-33

GEK 105054 Volume I 10-4.21


Bearing Handling

10-4.21.2

WARNING

CAUTION BALL AND ROLLER BEARINGS REQUIRE SPECIAL CARE TO PREVENT CORROSION. BEARINGS MUST NOT BE HANDLED WITH BARE HANDS NOR WITH ANY DEVICE THAT MIGHT CAUSE CONTAMINATION. CLEAN RUBBER OR NYLON GLOVES OR A PROTECTIVE HAND CREAM SHALL BE USED AT ALL TIMES WHEN HANDLING BEARINGS. 10-4.21.1

•

PRESERVATIVE OIL, MIL-C-6529, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED.

•

WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT OR COLD PARTS. CAUTION

Preservation WARNING

•

IMMEDIATELY AFTER INSTALLING OR REMOVING A CHILLED BEARING, USE A HEAT GUN TO RESTORE THE BEARING AND ANY ADJACENT COLD AREA TO ROOM TEMPERATURE SO THAT CONDENSATION OF MOISTURE WILL BE MINIMIZED. CHECK CAREFULLY FOR EVIDENCE OF MOISTURE AND CONTINUE HEATING UNTIL THE BEARING IS COMPLETELY DRY. APPLY PRESERVATIVE OIL, MIL-C-6529, TYPE III, AT ONCE TO THE BEARING AFTER COMPLETE DRYING. FAILURE TO REMOVE MOISTURE COULD CAUSE CORROSION TO ACCUMULATE ON BEARING WHICH COULD RESULT IN BEARING FAILURE.

•

WHEN HEAT IS REQUIRED TO RELIEVE SHRINK FITS OF BEARINGS, USE HEAT GUNS OR OVENS. DO NOT USE DIRECT-HEAT SOURCES TO APPLY THE HEAT AND DO NOT HEAT THE BEARINGS TO A TEMPERATURE HIGHER THAN 350°F (176.6°C). APPLY PRESERVATIVE OIL, MIL-C-6529, TYPE III, TO THE BEARINGS BEFORE HEATING AND AFTER THEY HAVE COOLED TO ROOM TEMPERATURE.

PRESERVATIVE OIL, MIL-C-6529, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED. At the point where bearings are accessible in the disassembly cycle, the bearings shall be thoroughly covered with preservative oil, MIL-C-6529, Type III. Use of engine lube oil as a lubricant or preservative is specifically prohibited. Personnel handling bearings must wear either synthetic rubber or nylon-mesh gloves with polyethylene palms and fingers. Bearings returned to storage shall be preserved with preservative, MIL-C-11796, Class 3, and wrapped in barrier paper, MIL-B-121, Grade A, Type I, Class 1, glossy side toward bearing. After installation, bearings shall be returned to room temperature and be preserved with preservative oil, MIL-C-6529.

10-34

Heating and Chilling



GEK 105054 Volume I

NOTE

CAUTION

Heating and chilling are defined as any temperature 10×F (6×C) or more above or below room temperature.

WHENEVER IT IS NECESSARY TO MARK ANY ENGINE PARTS, ONLY APPROVED MARKING COMPOUNDS SHALL BE USED. USE OF UNAUTHORIZED MARKING COMPOUNDS CAN CAUSE CORROSION WHICH CAN LEAD TO POSSIBLE PART FAILURE.

When it is necessary to chill a bearing in dry ice, the bearing shall be thoroughly coated with preservative oil, MIL-C-6529, Type III, and placed in a plastic bag prior to chilling. Immediately after installation of a chilled bearing, heat shall be applied with a heat gun until bearing and adjacent parts are brought to room temperature. Any moisture shall be removed using clean, dry shop air, and the bearing shall be protectively coated with preservative oil, MIL-C-6529, Type III. Heating of bearings shall be done using ovens or heat guns. No direct heat source, such as a blow torch, may be used. When the bearing returns to room temperature, it shall be protectively coated with preservative oil, MIL-C-6529, Type III. 10-4.22

Marking of Parts

Parts or assemblies designated as matched sets must be maintained as matched sets throughout maintenance activity. Set numbers, part numbers, and serial numbers shall be protected during cleaning or rework to prevent removal. When identification markings are removed or are no longer legible, the item must be re-marked per the appropriate marking method and at the location specified in the applicable Engine/Shop Manual or Service bulletin. There are two categories of marking: permanent and temporary.

Permanent marking of parts should be done in the area of lowest stress. Vibropeen is the acceptable method of permanent marking. Electric or chemical etch is not approved. CAUTION GREASE OR LEAD (GRAPHITE) PENCILS MUST NOT BE USED TO MARK COMBUSTION-SECTION OR HOT-SECTION PARTS. THESE MATERIALS PLUS HEAT CAN CAUSE PARTS MATERIAL DAMAGE. Temporary marking is not intended to withstand engine operation and is normally removed during or following maintenance procedures. Lead- and sulfur-containing materials should not be used for marking any parts. Preferred materials are listed below:

•

Chalk

•

White paint marker

•

Dykem - red, yellow, black

•

Ink - Justrite Slink Black; Marco S-1141, black

•

March Stencil Ink

•

Sharpie - black

•

Sharpie - blue

•

Dixon - black

•

Dixon - yellow

•

Dykem Steel Blue DX100

•

Soapstone Change 1


10-35

GEK 105054 Volume I 10-4.23


Blending

•

NOTE Refer to specific engine manual section or service bulletin for blend limits for the piece part under review. Use the limits in this procedure only when no specific limits are specified for the component in the engine manual or appropriate service bulletin. Blending is a repair procedure that is used to remove stress concentrations caused by nicks, scratches, or other sharp-edged damage marks on critical parts. Removal of the material surrounding the stress concentration, so that the sharp edges are blended into smooth contour, relieves the stress concentration and permits further use of the part by lessening the danger of cracking.

10-4.23.2

Blending General Practices

WARNING PARTICLES FROM GRINDING OR SANDING ABRADABLE MATERIAL COULD BE HARMFUL TO EYES AND RESPIRATORY TRACT. EYE AND RESPIRATORY PROTECTION IS REQUIRED. NOTE Refer to the inspection and repair limits for specific instructions on blending limits applicable to each part of the engine. a.

When blending compressor rotor blades, stator vanes, turbine blades, and similar parts, blend in a radial direction in relation to the engine. Avoid removing metal from leading and trailing edges of airfoil sections in such a way that the edges become thin or sharp; blend so as to maintain approximately the original contour.

b.

When blending a cylindrical part, blend in a circumferential direction, not along the axis of the part.

c.

The finish on the blended area must be as close to the original finish as possible.

The following rules for blending shall be observed, unless specific instructions to the contrary are given in the text: CAUTION DO NOT REPAIR TITANIUM PARTS WITH TOOLS, SUCH AS GRINDING WHEELS, FILES, STONES OR EMERY CLOTH, THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DAMAGE TO PARENT METAL COULD OCCUR.

•

Hand Blending

Sharp edges can be blended out using abrasive stones or papers, files, or crocus cloth. Coarse grades of abrasives or files may be used for fast metal removal, but the parts must then be given a smooth surface finish with fine grades of abrasives or crocus cloth.

Blending is also used to remove sharp edges resulting from machining, drilling, etc., and to restore the original contour and/or surface finish to parts that have been repaired by welding, brazing, etc. 10-4.23.1

The finish on the blended area must be as close as possible to the original finish of the part.

Defects more than 0.25 inch (6.4 mm) apart shall be blended separately. Those less than 0.25 inch (6.4 mm) apart (except splines) shall be blended together. Splines that are closer together than 0.25 inch (6.4 mm) and defects shall be repaired separately.

10-36



d.

When blending on a part involving a radius, keep the radius as specified in the repair section. If the radius is not specified, keep it as close as possible to the original contour. Refer to a similar part, if necessary, to determine original radius.

e.

Etch reworked area per paragraph 10-4.24 and inspect by spot fluorescent-penetrant method, per paragraph 10-4.25, after blending

10-4.23.3

GEK 105054 Volume I

a.

Rough out defects using coarse grades of resilient flexible abrasive impregnated wheels, brushes, or points. Use fine or extra fine grades to finish the blend areas.

b.

Follow the requirements described in paragraph 10-4.23.2 when doing power blending.

c.

Etch reworked area per paragraph 10-4.24 and inspect by spot fluorescent-penetrant method, per paragraph 10-4.25, after blending.

Power Blending

Blending on most parts may be done by using a power-driven polishing wheel or rubberbonded abrasive points, and any special instructions for the individual part must be followed.

10-4.23.4 Component Specific Requirements NOTE Requirements in specific engine manual section or appropriate service bulletin take precedence over the following procedures. The requirements in this section should be used with engine manual or service bulletin criteria or when no criteria are specified.

WARNING PARTICLES FROM GRINDING OR SANDING ABRADABLE MATERIAL COULD BE HARMFUL TO EYES AND RESPIRATORY TRACT. EYE AND RESPIRATORY PROTECTION IS REQUIRED. CAUTION

•

POWER BLENDING OF AIRFOIL SECTIONS MAY BE DONE ONLY WHEN SPECIFIED BY INDIVIDUAL PART INSTRUCTIONS.

•

WHEN DOING POWER BLENDING, BE SURE TO AVOID BUILDING UP EXCESSIVE HEAT AND RESULTING THERMAL STRESSES IN THE PART.

a.

Blending Airfoils. (l)

The types of airfoil damage described below may be repaired by hand blending or by power blending. Always refer to applicable part inspection paragraph for a description of airfoil defect limits as follows: (a) Nick – A V-shaped depression in the airfoil made by a sharp-edge object pushing the metal inward. (b)

Pit – A round sharp-edged hole with a rounded bottom caused by corrosion.

(c)

Scratch – A V-shaped line or furrow in the airfoil such as would be made by dragging a sharp object across the surface.

NOTE After power blending of a titanium part is completed, hand blend the same area approximately 0.002 inch (0.05 mm) deeper to remove any residual stresses in the surface material.


10-37

GEK 105054 Volume I

(2)

10-38


(d)

Dent – A smooth rounded depression in the airfoil made by impact with a rounded object. If there is any noticeable sharp discontinuity in the depression, it should be considered as a nick. Waviness of leading or trailing edge is to be treated as a dent.

(e)

Erosion – A sand- or shot-blasting effect on the leading edges or the leading portion of the concave side caused by sand or dust going through the engine.

(f)

Torn Metal – A separation or pulling apart of material by force, leaving jagged edges.

(c)

Defects more than 0.25 in (6.4 mm) apart shall be blended separately; those 0.25 in (6.4 mm) or less apart may be blended together. All blends must have a minimum radius of 0.25 in (6.4 mm). The total reduction in chord width may be taken on either side or divided between the sides. The amount of rework is controlled by the minimum chord width limit. The minimum allowable chord is given for root and tip of airfoil; the minimum chord at other points is proportional. To minimize the possibility of an engine stall, keep the shape of the blended airfoil leading edge as close as possible to the original contour (see Figure 10-17).

(d)

Blending limits are given as depth dimensions to make it easier to see how much can be repaired. Experience has shown that depth limits are used for most rework. However, the minimum chord limit is the most important dimension; it should be checked in borderline cases or where previous rework is evident in the same area. For convenience, the depth limits and minimum chord limits are given in both decimals and fractions. In borderline cases where depth limits and minimum chord limits conflict with one another, use the decimal minimum chord dimension to decide if the part is usable.

Hand-blending of airfoils may be done as specified below: (a)

Blending is done to remove stress caused by nicks, pits, and scratches to prevent blade failure. Remove high metal and straighten dents (where permitted) to restore the airfoil shape as closely as possible to its' original aerodynamic contour.

(b)

Blending shall be finished with fine stone or crocus cloth. Coarser tools may be used for initial removal of material. Finish blending in a direction along the length of the blade or vane and remove all evidence of marks across the airfoil that may have been made during initial blending.



GEK 105054 Volume I

Figure 10-17. Airfoil Leading Edge Blending (e) Defect limits are given as depth dimensions since this is the dimension that affects strength. However, accurate depth measurements require special equipment not normally available. Comparing the depth of a defect with the thickness of a leaf of thickness gage or with the thickness of a piece of safety wire is a reasonably accurate way of measuring depth (see Figure 10-18).

(f)

(3)

Swab etch reworked area per paragraph 10-4.24 and spot-fluorescent-penetrant inspect per paragraph 10-4.25. Brush or swab on penetrant where air passages are present to prevent excessive penetrant entrapment.

Power-blending of rotor blades, variable vanes, and vane segments may be done as follows: (a) To avoid damaging the airfoil, use masking tape and mask off the airfoil next to the rework area.


10-39

GEK 105054 Volume I


Figure 10-18. Airfoil Defect Measurement (b)

Use coarse grade, silicon-carbide impregnated rubber wheels and points for the initial benching of the blades and vanes. NOTE

During finish blending of defects, make a radius on both the leading and trailing edges of the airfoil. To do this, apply light pressure with the rubberized abrasive wheel, and let the cushion action of the wheel do both the blending of the radius and the buffing of the defect. (c)

10-40

(d)

Swab etch reworked areas per paragraph 10-4.24 and spot-fluorescent-penetrant inspect per paragraph 10-4.25.

(e)

Place the repaired blades and vanes in separate containers to prevent damage during handling.

(f)

Carefully inspect the blades and vanes.

Finish blending the defects, using the fine and extra fine grade of rubberized abrasive wheels. Remove only enough material to repair the defect.



b.

Blending Minor Indications in Tubing. (l)

(2)

c.

Use a fine abrasive stone, a small file, emery cloth, or crocus cloth for blending. Blend around the circumference of the tubing. The finished blend shall be as close as practical to the original finish of the part.

Removing High Metal. High metal is caused by the displacement of metal above a surface. It is found around defects like nicks and scratches. Remove high metal as follows:

GEK 105054 Volume I

(l)

Use a fine abrasive stone, a small file, emery cloth, or crocus cloth to remove high metal.

(2)

Remove only the material that is projecting above the original surface contour (see Figure 10-19).

(3)

Swab etch reworked area per paragraph 10-4.24 and spot-fluorescentpenetrant inspect per paragraph 10-4.25.

Figure 10-19. Blending and High Metal Removal


10-41

GEK 105054 Volume I 10-4.24


Swab Etching Procedure

NOTE Keep fresh solution is contact with the metal surface at all times by dipping the swab into the working solution periodically. Rub the swab continuously over the surface of the metal being etched, to prevent the formation of an inert sludge.

This procedure describes the materials and process for swab etching used as a preliminary step before fluorescent-penetrant inspection. Etching solutions are used as described herein or with exceptions as specified for individual parts in the Shop Manual. WARNING ETCHING SOLUTION CONTAINS ACID AND IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION, AND VAPOR CONTROL ARE REQUIRED. AVOID ALL CONTACT.

After etching, blot up etching solution from the metal surface with a clean paper towel or cloth.

e.

Gently wipe the etched area at least three times with a cloth or paper towel saturated with clean water. Blot dry with clean cloth or paper towel.

CAUTION

CAUTION

REFER TO THE MATERIAL SAFETY DATA SHEETS (MSDS) FOR STORAGE AND HANDLING INSTRUCTIONS FOR ETCHANT SOLUTION.

DO NOT POUR WORKING SOLUTION BACK INTO STOCK CONTAINER. ALTHOUGH THE SMALL QUANTITIES INVOLVED DO NOT ORDINARILY CONSTITUTE AN ENVIRONMENTAL HAZARD, FLUSH AWAY DISCARDED SOLUTIONS WITH SEVERAL VOLUMES OF WATER TO ENSURE ADEQUATE DILUTION.

a.

All surfaces to be etched must be free from oil, grease, scale, or other extraneous material.

b.

Pour a small quantity of stock solution into a clean plastic beaker or dish. This quantity will be the working solution, and is not to be returned to the stock bottle.

c.

d.

Saturate a cotton swab with the working solution, and swab the surface to be etched for 60 - 90 seconds, all Classes, except Class G. Class G etching time is 3 - 4 minutes. (Refer to MSDS for classification of etchant being used.). Keep the etching solution within defined boundaries of the area to be etched. Masking may be required to contain etchant to areas for etching.

10-42

f.

Discard used working solution, rinse, and dry plastic container for future use.

10-4.25 Spot-Fluorescent-Penetrant Inspection The spot-fluorescent-penetrant inspection process is intended for inspections at remote locations. It is a localized process, limited to small specific areas for inspection. It is not intended as a substitute for normal inspection. It is convenient to use for inspection of welded or other localized repair areas.



GEK 105054 Volume I

Personnel performing this inspection must be certified in accordance with MIL-STD-410, American Society of Non- Destructive Testing (ASNT-TC-IA), Air Transport Association Specification No. 105 (ATA 105), or locally approved certification program.

(4)

White light lamp for visual inspection of parts.

(5)

Time piece for timing operations.

(6)

Tools for inspection personnel:

Any training which may be provided by GE for a technique requiring the performance of this inspection method does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with MIL-STD-410, ASNT-TC-IA, or ATA 105. 10-4.25.1 Spot-Fluorescent-Penetrant Inspection Equipment/ Materials a.

Equipment required: (1)

(2)

(3)

Inspection booth, darkroom, or black cloth hood (for remote locations) to prevent excessive admission of white light. Compressed air supply for drying parts. Air supply must have filters to remove oil and moisture which can contaminate parts or inspection materials. Ultraviolet lamp to detect fluorescent indications. The ultraviolet (black) light source used for the detection of fluorescent indications shall have an intensity no less than 1,000 microwatts per sq. centimeter when measured at 15 inches. (381.0 mm). The black light should be check on a weekly basis or before use, whichever is less frequent.

b.

(a)

Three power and 10 power magnifying lenses.

(b)

Cotton swabs or small fine hair art brush to apply solvents for evaluating questionable indications.

Materials required: NOTE Qualified Products listed in MIL-I-25135 QPL (Qualified Products List) as Level 3, Method D, are considered acceptable alternates to the products listed. (1)

Post-Emulsification Flourescent-Penetrant Oils: ZL22A, B, or C, ZL27 or ZL27A (Magnaflux Corporation)

(2)

Hydrophilic Removers: ZR10A or ZR10B (Magnaflux Corporation)

(3)

Dry Powders: ZP4A or ZP4B (Magnaflux Corporation)

(4)

Non-Aqueous Wet Developers (NAWD): ZP9B, C, E, F, or D499C (Magnaflux Corporation).

(5)

Halogen-free solvents: Isopropyl Alcohol (TT-I-735) or Acetone (O-A51)


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GEK 105054 Volume I


10-4.25.2 Spot-Fluorescent-Penetrant Inspection Procedure

OR DIGESTIVE SYSTEM. PERSONAL PROTECTIVE EQUIPMENT REQUIRED WHEN HANDLING OR USING THIS MATERIAL. MAY LEAD TO ALLERGIC SENSITIVITY IN SOME INDIVIDUALS. THERMAL DECOMPOSITION MAY RELEASE TOXIC BY-PRODUCTS. PROVIDE LOCAL EXHAUST OR GENERAL DILUTION VENTILATION TO MEET PUBLISHED EXPOSURE LIMITS. IF THESE ARE NOT AVAILABLE, USE RESPIRATOR HAVING NIOSH APPROVAL FOR THE MATERIALS RELEASED.

This procedure is to be used wherever the shop manual calls out specific classes using either waterwashable or post-emulsifiable penetrant systems. NOTE

•

If visible color dye penetrant has been used on parts which are to be subsequently inspected with fluorescent penetrants, the contamination by the dye may prevent reliable fluorescent penetrant inspection. Any color dye indications evident by white light visual inspection shall be considered valid indications even if not detectable by ultraviolet light.

•

CAUTION TITANIUM ALLOY PARTS ARE SUBJECT TO STRESS CORROSION CRACKING WHEN RESIDUES OF HALOGEN CONTAINING COMPOUNDS REMAIN ON A PART THAT IS SUBSEQUENTLY SUBJECTED TO ELEVATED TEMPERATURES TYPICAL OF WELDING, HEAT TREATING, OR ENGINE OPERATION. THESE PARTS MUST BE THOROUGHLY CLEANED WITH NONHALOGEN COMPOUNDS AFTER EXPOSURE TO ANY HALOGEN CONTAINING COMPOUND TO PREVENT THE CRACKING AND POSSIBLE FAILURE OF PARTS.

Excessive white light may interfere with detection of a rejectable size indication. A test part having a known defect can be used to evaluate effectiveness of white light shielding.

a.

Parts must be cleaned of all traces of oil, grease, carbon, and rust scale prior to penetrant application.

b.

Apply penetrant oil with soft-bristle brush, cotton swab, or spray application. Allow a minimum of 30 minutes for penetration.

NOTE Indications of defects can be lost by use of excessive solvent.

WARNING ACETONE, O-A51 AND ISOPROPYL ALCOHOL, TT-I-735 ARE EXPLOSIVE WHEN SUBJECTED TO HIGH TEMPERATURE, SOURCE OF IGNITION, HIGH PRESSURE, OR OTHER CHEMICALS. FLAMMABLE NEAR SPARKS, OPEN FLAMES, WELDING AREAS, HOT SURFACES, OTHER SOURCES OF IGNITION, OR WHILE SMOKING. INHALATION, CONTACT, OR INGESTION MAY CAUSE IRRITATION OR BURNING OF RESPIRATORY SYSTEM, EYES, FACE, SKIN, 10-44

c.

Wipe off excess penetrant with a clean cloth using a solvent.



(1)

Alternate. Remove excess penetrant with a hydrophilic remover provided it belongs to the same family as the penetrant used. Do not exceed 90 seconds contact time. If remover is applied manually, do not scrub the surface of the part with the applicator. Use applicator only to deliver fluid to the part surface. WARNING

NONAQUAEOUS DEVELOPER IS MIXED IN A SOLVENT BASE CONTAINING ACETONE, ISOPROPYL ALCOHOL, AND/OR TRICHLOROETHANE. SOLVENTS ARE FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. AVOID BREATHING VAPORS AND USE IN A WELL-VENTILATED AREA. d.

Apply either dry powder or NAWD as a fine thin coating at ambient temperature to a dry surface. Allow a minimum of 10 minutes for developer to absorb penetrant before inspecting part.

e.

Evaluate any indication to the required inspection standards.

f.

Remove all residues by spraying, wiping, or soaking with approved solvents.

10-4.26 Miscellaneous Procedures CAUTION USE OF MOTOR-DRIVEN HYDRAULIC PUMPS TO OPERATE HYDRAULICALLY ACTUATED SPECIAL SUPPORT EQUIPMENT OTHER THAN TORQUE MULTIPLIERS IS NOT RECOMMENDED. EQUIPMENT DAMAGE CAN RESULT FROM IMPROPER POWER APPLICATION.

GEK 105054 Volume I

Use hand-operated hydraulic pumps to operate hydraulically actuated special support equipment such as pushers or pullers, unless otherwise specified. Exercise extreme care during assembly or disassembly operations to prevent entrance of pieces of safety wire, nuts, washers, or any other objects into the engine or assembly. If anything is dropped into the engine during assembly or disassembly, stop and remove the object before proceeding. Do not store tools or maintenance equipment on or against the engine. Account for and properly store all tools after use. Clean fittings of contamination before making or breaking connections. WARNING DO NOT USE EXTERNAL ENGINE PIPING AS A LADDER OR HANDHOLD WHILE PERFORMING MAINTENANCE. SERIOUS DAMAGE OR PERSONAL INJURY COULD RESULT. USE ONLY AUTHORIZED WORK STANDS AND PLATFORMS. CAUTION HANDLE ALL PARTS CAREFULLY. LIFT HEAVY PARTS WITH PROPER LIFTING FIXTURES AND A HOIST TO PREVENT DAMAGE TO PARTS AND PHYSICAL HARM TO PERSONNEL. Always use fiber or plastic blocks and hammers with plastic, rawhide, or nylon heads for driving operations.

Tie related parts together when removed. Tag or mark parts for identification. Change 1


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GEK 105054 Volume I


Coat parts to be stored for any length of time with an appropriate preservative.

WARNING

Verify identification of all mating parts.

PROLONGED EXPOSURE OF THE SKIN TO ENGINE LUBE OIL MAY BE DETRIMENTAL. WASH SKIN THOROUGHLY AFTER CONTACT AND REMOVE SATURATED CLOTHING IMMEDIATELY.

Observe tagged parts for proper location.

CAUTION

When installing or removing body-bound bolts, tap bolts straight through holes. Do not turn them.

During assembly, align matchmarks on all parts that were marked during disassembly. Keep all protectors, plugs, and caps installed until removal is required. Prior to final assembly, inspect all cavities and openings for foreign material. Inspect all mating flanges for foreign material prior to final assembly. Remove any high metal with a fine stone. CAUTION DO NOT MIX PLATED HARDWARE WITH UNPLATED HARDWARE. DO NOT USE SILVER OR CADMIUMPLATED TOOLS OR HARDWARE ON TITANIUM PARTS. PLATING CONTAINS SMALL QUANTITIES OF CHLORINE SALTS THAT ARE HARMFUL TO TITANIUM. Three types of tools (common, improvised, and special) are used to perform maintenance. Common tools are identified only when used in special applications. Drawings for improvised tools are incorporated in the text when such tools are required. Special tools are identified both by name and part number when required.

10-46

ENGINE LUBE OIL MAY SOFTEN PAINT OR STAIN CLOTHING. CLEAN SPILLED OIL FROM PAINTED SURFACES. Accessories, tubes, and hoses may have oil or fuel in them at time of removal. Drain these fluids from accessory being removed and cap all connecting hoses or tubes. Lubricate all gears and splines with engine lube oil before installation, unless otherwise specified. Prior to the installation of any part, a visual check should be made and any obvious signs of handling damage or abnormal wear should be noted and reported so that corrective action can be taken. Always read the complete operation and be sure you understand it fully. It is better to stop and ask than to continue and cause unnecessary work and/or damage. Do not disassemble any component any further than necessary to perform the required maintenance, even though complete disassembly instructions may be given. Remove piping and electrical leads only as required to perform maintenance tasks.



GEK 105054 Volume I

Attaching hardware (bolts, nuts, plain washers, brackets, clamps, etc.) is generally reusable. When possible, it is recommended that attaching hardware be left in place or temporarily reinstalled until the replacement component is installed. Parts or assemblies designated as matched sets elsewhere in this manual or by the parts list shall be maintained as a matched set throughout the maintenance cycle. Set numbers, part numbers, and serial numbers shall be protected during cleaning or repair to prevent removal. When identification is removed, or is no longer legible, the item shall be remarked per the original marking method and location for the part. When discrepancies are found during maintenance, refer to inspection tables for limits and corrective action. NOTE Mobile Assembly Fluid 403C may be used in place of soft petrolatum. Petrolatum, GE Specification A50TF142, shall be used as an assembly aid for tight-fitting parts, bearings, and packing, unless otherwise specified. Ordinary petrolatum (VV-P-236) shall not be used.

Change 1

10-47/(10-48 Blank)



GEK 105054 Volume I

CHAPTER 11 Preventive Maintenance 11-1

PURPOSE AND SCOPE

This chapter defines the requirements and frequency for performing preventive maintenance checks, inspections, and servicing. Motoring procedures, generally associated with maintenance, are also provided, as are definitions of terms used to evaluate equipment condition and damage during inspections. 11-2

GENERAL CHECKS AND INSPECTIONS

This section provides general guidelines, conditions, and definitions for conducting engine checks and inspections.

In addition to the regular inspections, there are those necessary when the GG or GT has been operated outside of the specified limits, for example, off-schedule variable geometry operation, overspeed, or overtemperature. There are also special inspections necessary for GGs or GTs exposed to abnormal conditions. These may include, for example, failures with significant damage and other abnormal exposure such as an installation fire or mishap during transportation, handling, or storage. Some abnormal conditions to which an engine may be exposed are:

•

Shock loading, collision impact, exposure to explosion, handling, or transportation mishap.

•

Structural overstress, or mounting system overload to GG or power turbine (PT) interface (e.g., earthquake or installation error).

•

Any equipment failure where parts are not contained within GG or PT, or where a major rotating component separates.

11-2.1 Special Inspections

•

Sudden seizure or stoppage of GG or PT rotor or driven equipment rotors.

The maintenance of the gas generator (GG) or gas turbine (GT) requires that inspection checks be made periodically. The inspection requirements and limits throughout this manual are based on operation within specified limits.

•

Excess G-loading during operation in excess of packager manual limits.

•

Significant inlet ingestion events (e.g., foreign objects causing significant flowpath damage, ice ingestion, or inlet system failure).

Preventive maintenance, servicing inspections, and checks are performed to reduce unscheduled shutdown time. Table 11-1 lists the frequency of these inspections and checks to be completed on the LM2500+ SAC engine. If the frequency of inspection/service requires change, coordinate with the packager. For terminology and definitions, refer to Table 11-2. Tables presented at the end of section 11-4.


GEK 105054 Volume I

•

Exposure to external fire, involving inlet system, exhaust system, base, enclosure, and equivalent.

•

Exposure to external fire in storage or transport.

•

Internal fire.

•

Thermal quench by water or other agent, or local overheating by fuel system failure.

•

Exposure to corrosive chemicals, fire-fighting agents, salt water, or sewage.

These events are highly variable and the exposure and associated damage which a GG or PT experiences is unpredictable. This prevents establishing a single, all-inclusive inspection and repair procedure. Depending upon circumstances of the event and instances of localization, limited damage can often be dispositioned by normal channels. For abnormal events, such as events listed above, execution of a special inspection workscope is necessary for proper restoration of serviceability. In some extreme cases, repair may not be possible or economical, and, therefore, further repair effort may not be advisable. Before proceeding with inspection and repair action to restore serviceability after a mishap, depot shall obtain service history of affected equipment and then contact the following for guidance: General Electric Company Marine & Industrial Engines Cincinnati, Ohio 45215-1988 USA ATTN: Customer Service Manager

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Assurance of a part’s serviceability is derived from control of material processing and manufacturing, operation within defined limits, and maintenance within defined limits and processes, as well as by inspection. Parts exposed to abnormal conditions may appear to be serviceable when in fact the actual state of the material cannot be ascertained even by the most advanced non-destructive testing and inspection methods. Parts which have been involved in an abnormal event shall be formally reviewed for severity of operation beyond normal working environment and dispositioned as to the necessity for a special inspection workscope. Since used replacement parts may be available which have operated in abnormal events, depot should verify that service histories of these parts are known and that, when applicable, required special inspections and part disposition following exposure to abnormal conditions have been completed and part is serviceable. Similarly, many components or assemblies from aircraft engines which have experienced previous flight service are not usable in LM engines. In addition, GT components which have experienced an extremely high number of start/stop cycles may not be usable. Specifically, use of used-serviceable flight or highcycle engine parts in the following categories is prohibited:

•

Rotating components.

•

Stator cases and stator vanes.

•

Frame assemblies, including sump components.

•

Main shaft bearings.

Prior to use of other components, contact General Electric (GE) Marine & Industrial Engines Customer Service about usability.



11-3

GEK 105054 Volume I

MOTORING

11-4

Although not required as part of normal starting procedures, motoring is frequently used following maintenance to check the engine prior to making a start. Motoring is performed with the fuel shutoff valves closed. Refer to Chapter 7, paragraph 7-4.3 of this volume, for motoring procedure.

IDLE CHECKS

Idle power functional checks are usually performed following any maintenance on the engine, lube, or fuel systems that involve the breaking of connections, the separation of flanges, or any action that could possibly affect operation of the GT system. Refer to Chapter 7, paragraph 7-3.6.h of this volume, for idle check procedure.

Table 11-1. Preventive Maintenance and Servicing Checks Frequency Weekly (Note 1)

Maintenance Item

Semi-Annual (Note 2)

Reference

Enclosure Inspection

X

X

Packager’s Manual

Lube and Scavenge Pump Inlet Screens and Magnetic Chip Detector Inspection and Cleaning

X

X

WP 400 00

X

Packager’s Manual

X

Packager’s Manual

Inlet Inspection

X

WP 401 00

External Engine Cleaning

X

WP 402 00

External Engine Inspection

X

WP 403 00

Exhaust Inspection

X

WP 404 00

Gas Turbine starter oil return line Screen Inspection (if installed) Supply and Scavenge Lube filter Inspection

(See Note 5) (On Condition)

Compressor Cleaning

(On Condition)

X

WP 405 00

Borescope Inspection

(On Condition)

X

WP 406 00

X

WP 407 00

Lube Oil Sampling (Note 4) Hydraulic Pump Filter Inspection

(See Note 5)

X

WP 408 00

Igniter Check

(On Condition)

X

WP 409 00

Vibration Monitoring System Functional Check

(On Condition)

X

WP 410 00


GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 11-1. Preventive Maintenance and Servicing Checks - (Cont.) Frequency Weekly (Note 1)

Maintenance Item


Reference

Overspeed Inspection

(On Condition)

WP 411 00

Overtemperature Inspection

(On Condition)

WP 412 00

Compressor Stall-Variable Stator Vane (VSV) Off-Schedule Inspection

(On Condition)

WP 414 00

Fuel System Inspection

X

WP 415 00

Thermocouple Inspection

X

WP 419 00

X

WP 417 00

High Pressure (HP) Recoup - Preferred Operating Range

(See Note 6)

Pneumatic Starter Servicing (Note 3) Variable Stator System Inspection

X X

X

WP 418 00

Redundant Overspeed System Check

X (See Note 8)

Packager’s Manual

Fabricated Thick Flange Turbine Mid Frame (TMF) (P/N L50533G01, G02) UT Inspection (See Note 9)

X

NOTES 1.

GE recommends certain preventive maintenance checks on a weekly basis; however, the user, for product efficiency purposes, may interpret this as a weekly or first opportunity thereafter frequency.

2.

GE recommends that semi-annual inspection interval not be exceeded on any items. Semi-annual inspections shall be made with engine shut down.

3.

An initial fill with 350 - 450 cm3 of lube oil is required before first operation. Refer to WP 122 00, Volume II, for specific instructions. GE supplied pneumatic starters are of a continuous lube type and no additional servicing is required. For other types of starters, consult the packager manual.

4.

Lube oil should be sampled at every engine changeout, periodic engine shutdowns, and maintenance, with a minimum monthly rate.

5.

Lube and hydraulic pump filters should be inspected whenever the differential pressure drop increases by 100 percent from clean condition.



GEK 105054 Volume I

Table 11-1. Preventive Maintenance and Servicing Checks - (Cont) Frequency Weekly (Note 1)

Maintenance Item


Reference

6.

HP recoup pressure check intervals: a. For engines with less than 500 hours since new or from last hot section replacement or overhaul, monitor HP recoup pressure and adjust orifice sizes as required at 100 hours intervals (up to 500 hours) per WP 417 00. b. For engines with over 500 hours but less than 2,000 hours since new or from last hot section replacement or overhaul, monitor HP recoup pressure and adjust orifice sizes as required at 500 hours intervals (up to 2,000 hours) per WP 417 00. c. For engines with over 2,000 hours since new or from last hot section replacement or overhaul, monitor HP recoup pressure and adjust orifice sizes as required at semiannual intervals per WP 417 00.

7.

PT thrust balance cavity pressure check intervals: Use same intervals as listed above for HP recoup pressure check. Adjust PT thrust balance cavity pressure per Volume II, WP 431 00.

8.

Semi-annually test the redundant overspeed protection system to verify it’s function using a simulated speed signal input.

9.

A certified ultrasonic inspector, with Level II or higher certification, should perform this UT inspection. Part-specific training required. Table 11-2. Definition of Terms Manual Terms

Associated Terms

Abrasion Wearing, grinding, or rubbing away of small amounts of material. Surface may be smooth or rough

Chafing, Fretting, Rub, Scuff, Wear

Blister A raised portion of a surface caused by separation of the outer layers of the parent material or of a coating

Bubble, Flaking, Oxide formation, Peeling, Scale, Slag inclusion (Weld)

Brinell (True) Often related to ball and roller bearings having been improperly installed or subjected to extremely high shock or impact loads at zero revolutions per minute. Usually occurs as a series of shallow depressions in the load area of the raceway

Dent

Brinell (False) A specialized form of fretting recognized by the occurrence of a series of shallow indentations in the race at each roller position on the loaded side of the bearing. Often red oxide of iron may be found where this has occurred 11-5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 11-2. Definition of Terms - (Cont.) Manual Terms

Associated Terms

Brittle A change in the resiliency of the parent material, usually due to aging, extreme heat, extreme cold, chemical action, or cold-working (metal)

Cold-worked, Hard (like an old packing), Stiff

Buckle A large-scale deformation of the original contour of a part, usually due to pressure or impact from a foreign object, structural stresses, excessive localized heating, high pressure differentials, or a combination of these

Ballooning, Bend, Blister (incorrect see Blister), Bulge, Crease, Curl, Dent (not to be confused with small area defect in heavy material [see Dent]), Depression, Distortion (usually refers to heavy material), Elongated (usually refers to outs of round), Fold, Indentation, Kink (usually results in crack: see Crack), Protrusion (hollow), Rupture (result of excessive buckling), Uneven, Warpage, Wrinkle

Bulge A raised portion or outward swelling on a surface, as from pressure

Hump, Protuberance

Burn A rapid, destructive, oxidizing action usually caused by higher temperatures than the parent material can structurally withstand. Change in color and appearance often indicates this condition

Burnout (see Missing piece), Erosion (chemical or grit), Guttered, Heatcheck, Heat curled, Heat deterioration, Hole (burn), Hot spot, Overheated, Oxidation

Burr A rough edge or a sharp edge on the surface of the parent material Chafing A rubbing action between parts having limited relative motion (as in vibration)

Abrasion, Fretting, Rub, Wear

Chip A breaking away of the edge of the parent material, usually caused by heavy impact from a foreign object

Break, Nick (similar to Chip, but no parent material is removed [see Nick])

Coking An accumulation of carbon

Carbon buildup

Corrosion The gradual conversion of material to another compound due to chemical attack. It appears as a mass of small pits due to the loss of the formed compound from the affected surface which cumulatively creates a cavity (usually shallow) in the surface of the parent material

Sulfidation



GEK 105054 Volume I

Table 11-2. Definition of Terms - (Cont.) Manual Terms

Associated Terms

Crack A parting of the parent material

Break, Crater (usually found in castings), Fatigue damage, Fissure, Fracture, Inclusion (usually found in castings), Lap (usually found in forging), Rupture, Separation, Shear (not usually considered a crack: see Missing Piece), Slit, Tear

Craze A mesh of fine cracks on a surface or glaze defined as numerous superficial surface cracks which have no significant width or depth

Fine cracks around bolt holes or surface edges that are subject to stresses or pressure. Fine cracks in metal, paint surfaces, seal edges, plastics, windows, sight glasses, coatings, etc.

Dent A completely smooth surface depression caused by pressure or impact from a smooth, balllike foreign object. Parent material is displaced, but usually none is separated

Peen

Deviation A condition which causes a port to differ from the manufacturer's blueprint

Damage, Defect, Flow, Imperfection, Irregularity

Erosion The gradual wearing away of material caused by the hot flow of gases or foreign particles. An eroded surface may appear similar to a corroded surface Flake A thin, chip-like or scale-like layer of metal Fretting Wear, in a rippled pattern, caused by friction

Chafing, Abrasion

Gall A defect caused by the movement of two surfaces in contact with each other. In most cases an accumulation of foreign material is deposited on the parent material

See Pickup

Gouge A wide, rough scratch or group of scratches, usually with one or more sharply impressed corners and frequently accompanied by deformation or removal of parent material


GEK 105054 Volume I


Groove A long, narrow, continuous cavity or impression caused by pressure of a moving surface in contact with the parent material

Associated Terms If impression is shallow and smooth, see Wear

Imbalance The state of being out of balance. An unequal distribution of weight about the axis of rotation Loose Abnormal movement of a part

Backed out, Excessive movement, Excessive play, Insecure, Leaks, Loose fit, Not tight, Not torqued, Shakes, Sloppy, Rattles, Unbuttoned, Unpinned

Misaligned Mismatch or malformation of any part that either prevents perfect assembly or results in faulty operation and/or ultimate part failure

Eccentric, Not axial, Not concentric, Out-of-round, Unmatched, Unsquare

Missing Piece Removal or loss of a portion of parent material due to a combination of defects or damage

Break (two or more pieces), Burn (burned away), Burnout, Corrosion (eaten away), Erosion (worn away), Guttered, Hole, Rusted (rusted away), Sheared, Smashed, Torn (torn away)

Nick A surface impression with sharp comers or bottom, usually caused by pressure or impact from a sharp-edged foreign body. Parent material is displaced, but usually none is separated

Chip (see Chip), Dent (see Dent), Notch (see Chip)

Noisy An abnormal sound condition of moving parts, usually an increase in volume or a change of pitch

Bumps (sound), Chatters, Clicks, Grates (usually gears), Grind, Hums, Loud, Rattles (usually loose parts), Rubs (sound of rubbing), Scrapes (sound of scraping), Screeches, Squeals, Thumps (sound), Whistles

Obstructed Prevention of free flow of a fluid (air, oil, fuel, water) because of foreign material in the flowpath or malformation in the flow member

Clogged, Contaminated, Plugged, Restricted



GEK 105054 Volume I

Table 11-2. Definition of Terms - (Cont.) Manual Terms

Associated Terms

Oxidation A surface deterioration by the chemical reaction between oxygen in the air and the metal surface. Attack is manifested as red rust in iron and low alloy steels when formed at ambient temperature. Oxides which form on super alloys are complex and can be green or black depending on material composition and the temperature at which it is formed

Burn, Rust

Pickup Transfer of one material into or upon the surface of another, caused by contact between moving parts or deposits of molten material on a cooler material

Burr (usually tool-tub leaving high parent material), Gall, High spot, Imbedment, Inclusion (usually pick-up of a dissimilar foreign material), Pileup, Protrusion (deposit on parent material), Metallization

Pinched Distortion of one or more surfaces of the parent material, caused by pressure

Bound, Compressed, Flattened, Seized (see Seizure), Smashed (without separation into pieces), Squashed, Squeezed, Tight

Pit A minute depression or cavity with no sharp, high-stress comers in the surface of the material. Pits are usually caused by chemical reaction (rusting and chemical corrosion)

Corrosion, Crater (usually in weld or casting), Dent (incorrect: see Dent), Electrolytic cavity, Erosion (usually results in hole: see Burns), Fretting (see Wear), Inclusion (as in sand castings), Oxidation (usually in weld), Pock-marked, Spalled, Roughness

Rub A surface cavity or impression caused by two surfaces moving against each other

If impression is shallow and smooth, see Wear. If impression is sharp, see Scratch

Scratch A long, narrow, sharp-cornered impression caused by the movement of a sharp object across the surface of the parent material

Abrasion, Chafe, Furrow, Groove, Rub, Scarf, Score

Scuff A surface roughened by wear

Scrape, Scratch

Seizure A welding or binding of two surfaces that prevents further movement

Bound up, Frozen, Tight (see Pinched), Tight (fit), Wedged, Welded (without external assistance)

Sheet-Metal Dent A large-area, smooth depression in the parent material

See Buckle


GEK 105054 Volume I


Associated Terms

Shingling Two adjacent surfaces overlapping when normal position is edge-to-edge or face-to-face contact Spall Broken or crushed material due to heat, mechanical, or structural causes. Chipping of small fragments under the action of abrasion

Chip

Spatter A thin deposit of molten metal, usually on airfoil surface downstream from a burn area or coating deposit

Splatter, Splash

Sulfidation A form of hot corrosion in heat-resistant alloys by the reaction at the metal surface of sodium chloride (sea air) and sulfur (from fuel). Attack usually occurs over a broad front and can be identified as gray to black blisters (early stage) or surface delamination (advanced stages)

Hot corrosion



GEK 105054 Volume I

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

b

Critical life-limited parts are those parts whose sudden failure could threaten the structural integrity of the engine or its package. Stress cycles on gas turbine parts result from transients of speed and temperature that occur during starts, accelerations, and decelerations. Therefore, life limits are expressed in terms of engine cycles and can be related to normal operational data.

c.

Cycles are defined in paragraph 12-2, DEFINITIONS. Life limits of critical parts are established through analysis and testing. Accumulated cycles are to be calculated, tracked, and compared to published declared life limits to determine when a part should be permanently retired from service. No component shall be allowed to remain in service beyond its published life limit in any application. Paragraph 12-5 defines how cycles are to be calculated.

d.

GE critical life-limited parts have undergone extensive analysis which provides a basis for establishing the life limits defined in Table 12-1. GE will continue evaluating component life limits and will revise this chapter when life limit changes can be technically justified.

e.

The critical parts life limitations have been substantiated based on engineering analysis that assumes this product will be operated and maintained using the procedures and inspections provided in the instructions for continued operation supplied with this product by GE, or its licensees. For Life Limited Parts and parts that influence Life Limited Parts, any repair, modification or maintenance procedures not approved by GE, or its licensees, or any substitution of such parts not supplied by GE, or its licensees, may materially affect these limits.

CAUTION

•

CRITICAL LIFE-LIMITED PARTS MUST BE REMOVED FROM SERVICE BEFORE REACHING THEIR DECLARED LIFE LIMIT.

•

UNDER NO CIRCUMSTANCES SHALL ANY PREVIOUSLY USED CRITICAL LIFE-LIMITED PART BE INSTALLED INTO A LM2500+ GAS TURBINE OR GAS GENERATOR WITHOUT DOCUMENTED KNOWLEDGE OF PAST CYCLIC OPERATIONAL HISTORY OF THE PART.

•

•

a.

NO PART PREVIOUSLY OPERATED IN A NON-COMMERCIAL MARINE GAS TURBINE OR GAS GENERATOR SHALL BE INSTALLED INTO A COMMERCIAL MARINE GAS TURBINE. SERIOUS ENGINE DAMAGE CAN OCCUR IF ALL PROVISIONS OF THIS CAUTION ARE NOT COMPLIED WITH. This chapter identifies specific parts of the LM2500+ industrial gas turbine that are cyclic life-limited as a result of exposure to normal operating conditions. This chapter provides instructions for tracking the operating hours and operating cycles for such parts that have been identified by GE as being limited in terms of operating service life.


GEK 105054 Volume I 12-2 DEFINITIONS a.

b.

c.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 12-3 AFFECTED PARTS

Full Cycle: A full cycle is defined as an engine start from zero gas generator speed to high power (greater than 8,000 RPM), followed by a shutdown of the gas turbine. Partial Cycle: A partial cycle is defined as a decrease from high power (greater than 8,000 RPM) to gas generator idle (less than 6,800 RPM), followed by an increase to high power (greater than 8,000 RPM). Trip (or stop-cock) cycle: A trip or stopcock cycle is defined as a cycle from zero gas generator speed, with acceleration to high power setting (any power setting above idle), followed by a rapid (uncontrolled) shutdown.

d.

Declared Life: Declared life is the cyclic life limit of a critical life-limited part.

e.

Accumulated Cycles: Accumulated cycles represent the calculated life consumed by a part, considering full, partial, and trip cycles seen by the part during operation.

CAUTION CRITICAL LIFE-LIMITED PARTS SHALL NOT BE OPERATED BEYOND THE PUBLISHED DECLARED LIFE LIMITS. SEVERE ENGINE DAMAGE COULD RESULT FROM FAILURE TO COMPLY. The critical life-limited parts for the LM2500+ Industrial Engine are listed in Table 12-1. 12-4 PARAMETERS TO BE TRACKED a.

Engine operating hours and cycles must be recorded and tracked for each critical lifelimited part. Each part is uniquely identified by the combination of its part number and serial number. Parameters to be tracked are shown in the Critical Parts Tracking System Data Sheet shown in Figure 12-1. A data sheet must be created and maintained for each critical part throughout its entire life. CAUTION IT IS THE OWNER’S/USER’S RESPONSIBILITY TO ESTABLISH A TRACKING SYSTEM TO ENSURE THAT ADEQUATE RECORDS ARE MAINTAINED FOR EACH CRITICAL LIFE-LIMITED PART AND THAT NO SUCH PART EXCEEDS ITS LIFE LIMIT.

b.

When any critical life-limited part is transferred from one location to another or used as a rotable spare, this event must be recorded on the Critical Parts Tracking System Data Sheet for that part. The data sheet, containing the life history record of a critical life-limited part, maintains documentation of the part’s cyclic life history as the part transfers from one location to another.



GEK 105054 Volume I The coefficients Kf, Kp, and Ksc are listed for each component in Table 12-1. A part shall be permanently removed from service prior to the accumulated cycles reaching the declared life limit of the component listed in Table 12-1.

12-5 CALCULATING ACCUMULATED CYCLES AND RECORDING DATA a.

As defined in paragraph 12-2, a cycle may be designated as a full, partial, and trip cycle. In order to take credit in most cases for the increased capability of a partial cycle, the life consumed is calculated by considering full, partial, and trip cycles. The consumed life of the part is designated as the accumulated cycles on the part. Accumulated cycles are calculated using the following equation:

b.

Accumulated Cycles = Kf x (Full Cycles) + Kp x (Partial Cycles) + Ksc x (Trip or Stop-cock Cycles)

The owner/user is responsible for the maintenance of accurate records of all engine hours and cycles. The owner/user should monitor status of the parts to ensure that none listed in Table 12-1 exceed the declared life limits published in this chapter.

c.

The owner/user is responsible for documenting the history of critical life-limited parts in such a way as to make possible a historic record between part numbers and serial numbers and their respective assembly and/or engine.

Table 12-1 Declared Life Limits for the LM2500 Plus Engine Module

Component

Part Number

Industrial Declared Life Kf Limits

Kp

Ksc

Stage 0 Blisk

K070P02

17,800

1.0

N/A

N/A

Stage 1 Disk

L50507P01-P02

3,800

1.0

N/A

N/A

Stage 1 Disk

L50507P03

14,000

1.0

N/A

N/A

Stage 1-2 Spacer

L50588P01-P03

5,200

1.0

N/A

N/A

Stage 1-2 Spacer

L50588P04

4,900

1.0

N/A

N/A

Stage 2 Disk

L44742P01

6,100

1.0

N/A

N/A

Stage 2 Disk

L50508P01-P02

5,400

1.0

N/A

N/A

Stage 3-9 Spool

9021M64P13-P14 10,100

1.0

N/A

N/A

Stage 10-13 Spool

L50509G01-G04

7,800

1.0

N/A

N/A

Stage 14-16 Spool

L50510P01

4,900

1.0

N/A

N/A

Stage 14-16 Spool

L50510P03

7,200

1.0

N/A

N/A

Stage 14-16 Spool

L50510P04

5,800

1.0

N/A

N/A

CDP Seal

L50513P01

12,900

1.0

N/A

N/A

CDP Support

L50514P01

20,000

1.0

N/A

N/A

HPCR


GEK 105054 Volume I


Table 12-1 Declared Life Limits for the LM2500 Plus Engine (Continued) Module

Component

Part Number

Industrial Declared Life Kf Limits

Fwd Shaft

9208M79P09

6,600

1.0

N/A

N/A

Stage 1 Disk

L47518P01

12,100

1.0

N/A

N/A

Stage 2 Disk

L47520P01

5,300

1.0

N/A

N/A

Spacer

L47519P04

5,900

1.0

N/A

N/A

Rear Shaft

L31304P03

5,600

1.0

N/A

N/A

Stage 1 Disk

L50501P02

TBD

1.0

N/A

N/A

Stage 2 Disk

L50502P02

TBD

1.0

N/A

N/A

Stage 3 Disk

L50503P01

TBD

1.0

N/A

N/A

Stage 4 Disk

L50504P01

TBD

1.0

N/A

N/A

Stage 5 Disk

L50505P01

TBD

1.0

N/A

N/A

Stage 6 Disk

L50506P01

TBD

1.0

N/A

N/A

Fwd Shaft

L21497P08

TBD

1.0

N/A

N/A

Aft Shaft

L50525P02

TBD

1.0

N/A

N/A

BP Seal

L16742P02

TBD

1.0

N/A

N/A

BP Support

L14475P02

TBD

1.0

N/A

N/A

Kp

Ksc

HPTR

LPTR



GEK 105054 Volume I

Figure 12-1 Critical Parts Tracking System Data Sheet Example



GEK 105054 Volume I

APPENDIX A Gas and Liquid Fuel, Water, Steam, and Detergent Requirements This appendix contains specifications for the following: A1

Natural Gas Fuel

A2

Liquid Fuel

A3

Water Purity - NOx Suppression

A4

Water Purity - Compressor Cleaning

A5

Liquid Detergent - Compressor Cleaning

A6

Lubricating Oil

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

MID-TD-0000-1 September 2009

5

MID-TD-0000-1November 2001

Appendix A1 Fuel Gases for Combustion in GE AeroDerivative Gas Turbines GE AeroDerivative gas turbines have the ability to burn a wide range of gaseous fuels, as shown in Table A1-1. These gases present a broad spectrum of properties due to both active and inert components. This specification is designed to define guidelines that must be followed in order to burn these fuels in an efficient, trouble-free manner, while protecting the gas turbine and supporting hardware.

A1-1 Applicable Documents Table A1-2a identifies the fuel composition limits for aeroderivative gas turbines with Dry Low Emission (DLE) combustion systems and Table A1-2b identifies the fuel composition limits for aeroderivative gas turbines with Standard (Single Annular Combustor [SAC]) combustion systems. Table A1-3 identifies the acceptable test methods to be used in determining gas fuel properties.

2. Values and limits apply at the inlet of the gas fuel control module. 3. Heating value ranges shown are provided as guidelines. Specific fuel analysis must be furnished to GE for evaluation. The standard configured single annular combustor (SAC) gas turbines require a fuel with a Low Heating Value (LHV) no less than of 6500 Btu/pound. The Dry Low Emissions (DLE) combustion system requires a minimum LHV of 18,000 Btu/pound. (Reference Section A1-3.1) 4. The fuel gas supply shall be 100% free of liquids. Admission of liquids can result in combustion and/or hot gas path component damage. (Reference Section A1-3.3) 5. Modified Wobbe Index (MWI), is described in Section A1-3.2.

The following should be noted and apply to Tables A1-1, A1-2a, and A1-2b: 1. When considering the use of alternate fuels, provide details of the fuel constituents, fuel pressure, fuel temperature, and expected engine usage conditions and operating characteristics to GE for evaluation and recommendations.


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Table A1-1. Fuel Classification LHV Btu/scf

Major Components

Pipeline Natural Gas and Liquefied Natural Gas

800 - 1200

Methane

Liquefied Petroleum Gas

2300 - 3200

Propane, Butane

- Air Blown

100 - 150

Carbon Monoxide, Hydrogen, Nitrogen, Water Vapor

- Oxygen Blown

200 - 400

Carbon Monoxide, Hydrogen, Water Vapor

300 - 3000

Methane, Hydrogen, Carbon Monoxide, Ethane, Ethene, Propane, Propene, Carbon Dioxide, Nitrogen

Fuel

Gasification Gases

Process Gases

Table A1-2a. Fuel Gas Composition Limits for DLE Configuration Parameter

Requirements - DLE Configuration Minimum

Maximum

40 (See Note 2)

60

50% Vol

100% Vol

LM1600

0

35% Vol

LM2500 / LM2000

0

35% Vol

LM2500+G4

0

30% Vol

LM6000 / LMS100

0

24% Vol

Hydrogen (H2)

0

5% Vol (See Note 2)

Diolefins (i.e. Butadiene, Propadiene)

0

None allowed

Other combustibles (See Note 3)

0

Consult GE

Modified Wobbe Index (See Note 1) Methane (CH4) Ethane (C2+ paraffins)

Notes: 1.

MWI at max limits C2+.

2.

Other levels may be possible. Consult GE.

3.

Other combustibles - CO, olefin hydrocarbons, etc.

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MID-TD-0000-1 September 2009 Table A1-2b. Fuel Gas Composition Limits for SAC Configuration Parameter

Requirements - SAC Configuration Minimum

Maximum

LMS100 Low MWI Nozzles

35

44

LMS100 Standard MWI Nozzles

45

60

All Other LM

40

60

LM2500 / LM2000

0

85% Vol

LM2500+ / +G4 / LM1600 / LM5000

0

75% Vol

LM6000 / LMS100

0

35% Vol

Diolefins (i.e. Butadiene, Propadiene)

0

See Note 3

Olefins

0

15% Vol (See Note 4)

Other combustibles (See Note 5)

0

Consult GE

Modified Wobbe Index (See Note 1)

Hydrogen + 1/2 CO (H2 + 1/2 CO) (See Note 2)

Notes: 1.

Expanded values may be possible with fuel nozzle modifications. Consult GE.

2.

High hydrogen and carbon monoxide content fuels have large rich to lean flammability limits. These types of fuels often require inert gas purging of the gas turbine gas fuel system upon unit shutdown or a transfer to a more conventional fuel. When process gas fuels have extreme flammability limits such that the fuel will auto ignite at turbine exhaust conditions, a more “conventional” start-up fuel, such as methane, is required.

3.

The presence of even trace amounts of butadiene in the gas fuel may cause fuel system fouling. Additional fuel system maintenance may be required when using fuels containing butadiene.

4.

Olefins in the gas fuel at moderate levels (<15%) are not expected to present problems as long as the fuel temperature is kept below 176°F (80°C). With a higher level of olefins or with a higher gas fuel temperature, fuel system fouling may be an issue.

5.

Other combustibles - CO, hydrocarbons. etc.


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MID-TD-0000-1 September 2009 Table A1-3. Test Methods for Gaseous Fuels PROPERTY Gas Composition

ACCEPTABLE METHODS ASTM D1945 - Standard Method for Constituents of Gases by Gas Chromatography, or ISO 6974 - Natural Gas -- Determination of Composition from C1 to C8 with Defined Uncertainty By Gas Chromatography ISO 6975 - Natural Gas -- Determination of Hydrocarbons from Butane (C4) to Hexadecane (C16) -Gas Chromatographic Method

Heating Value Specific Gravity Compressibility Factor

ASTM D3588 - Procedure for Calculating Calorific Value and Specific Gravity of Gaseous Fuels, or ISO 6976 - Natural gas -- Calculation of Calorific Values, Density, Relative Density and Wobbe Index from Composition GPA 2172 - Calculation of Gross Heating Value, Relative Density and Compressibility Factor for Natural Gas Mixtures from Compositional Analysis

Dew Point (See Note 1)

ASTM D1142 - Water Vapor Content of Gaseous Fuels by Measurement of Dew Point Temperature

Sulfur

ASTM D1072 - Total Sulfur in Fuel Gases by Combustion and Barium Chloride Titration, or ASTM D3246 - Sulfur in Petroleum Gas by Oxidative Microcoulometry (See Note 2) ASTM D5504 - Sulfur Compounds in Natural Gas and Gaseous Fuels by Gas Chromatography and Chemiluminescence ASTM D6667 - Determination of Total Volatile Sulfur in Gaseous Hydrocarbons and Liquefied Petroleum Gases by Ultraviolet Fluorescence ASTM D6968 - Simultaneous Measurement of Sulfur Compounds and Minor Hydrocarbons in Natural Gas and Gaseous Fuels by Gas Chromatography and Atomic Emission Detection

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MID-TD-0000-1 September 2009 Table A1-3. Test Methods for Gaseous Fuels (Continued) PROPERTY Sulfur (continued)

ACCEPTABLE METHODS ISO 4260 - Petroleum Products and Hydrocarbons Determination of Sulfur Content - Wickbold Combustion Method ISO 6326 - Natural Gas -- Determination of Sulfur Compounds ISO 19739 - Natural Gas -- Determination of Sulfur Compounds using Gas Chromatography IP 243 - Petroleum Products and Hydrocarbons Determination of Sulfur Content - Wickbold Combustion Method

Chemical Composition

ASTM D2650 - Chemical Composition of Gases by Mass Spectrography

ASTM - ASTM International ISO - International Organization for Standardization GPA - Gas Processors Association IP - Institute of Petroleum UK Notes: 1.

Hydrocarbon and water dew points shall be determined by direct dew point measurement (Chilled Mirror Device). If dew point cannot be measured, an extended gas analysis, which identifies hydrocarbon components from C1 through C14, shall be performed. This analysis must be accurate within 10 ppmv. A standard gas analysis to C6+ is normally not acceptable for dew point calculation unless it is known that heavier hydrocarbons are not present, as is most often the case with liquefied natural gases.

2.

This test method will not detect the presence of condensable sulfur vapor. Specialized filtration equipment is required to measure sulfur at concentrations present in vapor form. Contact GE for more information.


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A1-2 Fuel Gas Classification

A1-2.1.2 Liquefied Natural Gas

A1-2.1 Natural Gas, Liquefied Natural Gas (LNG), Medium BTU Natural Gas, and Liquefied Petroleum Gas (LPG) Natural gases are predominately methane with much smaller quantities of the slightly heavier hydrocarbons, such as ethane, propane, and butane. Liquefied petroleum gas is propane and/or butane with traces of heavier hydrocarbons.

Liquefied natural gas (LNG) is produced by drying, compressing, cooling and expanding natural gas to approximately -260°F at 14.7 psia (-162.2°C at 101.4 kPa). The product is transported as a liquid and delivered as a gas after pressurizing and heating to ambient temperature. The composition is free of inerts and moisture and can be treated as a high quality natural gas. LNG can pick up moisture that is present in the pipeline but it is not a source of the moisture.

A1-2.1.1 Pipeline Natural Gas

A1-2.1.3 Medium BTU Natural Gas

Natural gases normally fall within the calorific heating value range of 800 to 1200 Btu/scf (31419-47128 kJ/NM3) lowest heating value (LHV).

Natural gases are found in and extracted from underground reservoirs. These "raw gases" may contain varying degrees of nitrogen, carbon dioxide, hydrogen sulfide, and contaminants such as salt water, sand, and dirt. The heating values of medium Btu natural gas normally fall between 400 and 800 Btu/scf (15710-31419 kJ/NM3) (LHV). Processing by the gas supplier normally reduces and/or removes these constituents and contaminants prior to use in the gas turbine. A gas analysis must be performed to ensure that the fuel supply to the gas turbine meets the requirements of this specification.

Actual calorific heating values are dependent on the percentages of hydrocarbons and inert gases contained in the gas. Natural gases are found in and extracted from underground reservoirs. These "raw gases" may contain varying degrees of nitrogen, carbon dioxide, hydrogen sulfide, and contaminants such as salt water, sand, and dirt. Processing by the gas supplier normally reduces and/or removes these constituents and contaminants prior to distribution. A gas analysis must be performed to ensure that the fuel supply to the gas turbine meets the requirements of this specification.

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A1-2.1.4 Liquefied Petroleum Gases The heating values of LPGs normally fall between 2300 and 3200 Btu/scf (90330125676 kJ/NM3) (LHV). Based on their high commercial value, these fuels are normally utilized as a backup fuel to the primary gas fuel for gas turbines. Since LPGs are normally stored in a liquid state, it is critical that the vaporization process and gas supply system maintains the fuel at a temperature above the minimum required superheat value. Fuel heating and heat tracing are required to ensure this.



A1-2.2 Gasification Fuels

A1-2.2.2 Air Blown Gasification

Other gases that may be utilized as gas turbine fuel are those formed by the gasification of coal, petroleum, coke, or heavy liquids. In general, the heating values of gasification fuels are substantially lower than other fuel gases. These lower heating value fuels require that the fuel nozzle gas flow passages be larger than those utilized for fuels of higher heating values.

Gases produced by air blown gasification normally have heating values between 150 and 200 Btu/scf (5907-7876 kJ/NM3) (LHV). The H2 content of these fuels can range from 8 percent to 20 percent by volume and have a H2/CO mole ratio of 0.3 to 3:1. The use and treatment of these fuels are similar to that identified for oxygen blown gasification.

Gasification fuels are produced by either an Oxygen Blown or Air Blown gasification process. A1-2.2.1 Oxygen Blown Gasification The heating values of gases produced by oxygen blown gasification fall in the range of 200 to 400 Btu/scf (7876-15752 kJ/NM3). The hydrogen (H2) content of these fuels is normally above 30 percent by volume and have H2/CO mole ratio between 0.5 and 0.8. Oxygen blown gasification fuels are often mixed with steam for thermal nitrous oxide (NOx) control, cycle efficiency improvement, and/or power augmentation. When utilized, the steam is injected into the combustor by an independent passage. Due to high hydrogen content of these fuels, oxygen blown gasification fuels are normally not suitable for DLE applications.

For gasification fuels, a significant part of the total turbine flow comes from the fuel. In addition, for oxygen blown fuels, there is a diluent addition for NOx control. Careful integration of the gas turbine with the gasification plant is required to assure an operable system. Due to the low volumetric heating value of both oxygen and air blown gases, special fuel systems and fuel nozzles are required. A1-2.3 Process Gases Many chemical processes generate surplus gases that may be utilized as fuel for gas turbines (i.e. tail or refinery gases). These gases often consist of methane, hydrogen, carbon monoxide, and carbon dioxide that are normal by-products of petrochemical processes. Due to the hydrogen and carbon monoxide content, these fuels have large rich-to-lean flammability limits. These types of fuels often require inert gas purging of the gas turbine gas fuel system upon unit shutdown or transfer to a more conventional fuel. When process gas fuels have extreme flammability limits such that the fuel will auto ignite at turbine exhaust conditions, a more conventional startup fuel, such as methane, is required.


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Additional process gases utilized as gas turbine fuels are those which are by-products of steel production. These are: A1-2.3.1 Blast Furnace Gases Blast Furnace Gases (BFG), alone, have heating values below minimal allowable limits. These gases must be blended with other fuel to raise the heating value to above the required limit. Coke oven and/or natural gases or hydrocarbons such as propane or butane can be utilized to accomplish this. A1-2.3.2 Coke Oven Gases Coke oven gases are high in H2 and H4C and may be used for SAC systems, but are not suitable for DLE combustion applications. These fuels often contain trace amounts of heavy hydrocarbons which, when burned, could lead to carbon buildup on the fuel nozzles. The heavy hydrocarbons must be "scrubbed" or removed from the fuel prior to delivery to the gas turbine or maintained in the gaseous state.

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A1-2.3.3 Flare Gases Flare Gases are produced by a number of associated gas activities including oil wells or oil rigs, refineries, chemical plants, and landfills. Associated gases from oil production and refineries are normally flared, but can also be a good fuel source for power production. These associated gases can be high in methane and C2+ gases and must be evaluated on a case by case basis by GE. Refinery gases are also known to contain butadienes which must be removed prior to use. Gases produced from chemical plants are usually the result of a chemical reaction and will vary in heating value depending on the composition and process. In landfills, gas which results from the decomposition of materials buried in the landfill can also be a source fuel for power production. These types of gases are usually in the low to medium heating value range (300-450 Btu/scf) and normally contain siloxanes.



A1-3 Fuel Properties A1-3.1 Heating Value A fuel's heat of combustion, or heating value, is the amount of energy, expressed in Btu (British thermal unit), generated by the complete combustion, or oxidation, of a unit weight of fuel. The amount of heat generated by complete combustion is a constant for a given combination of combustible elements and compounds. For most gaseous fuels, the heating value is determined by using a constant pressure, continuous-type calorimeter. This is the industry standard. In these units, combustible substances are burned with oxygen under essentially constant pressure conditions. In all fuels that contain hydrogen, water vapor is a product of combustion, which impacts the heating value. In a bomb calorimeter, the products of combustion are cooled to the initial temperature and all of the water vapor formed during combustion is condensed. The result is the HHV, or higher heating value, which includes the heat of vaporization of water. The LHV, or lower heating value, assumes all products of combustion, including water, remain in the gaseous state, and the water heat of vaporization is not available. It is a common practice in the gas turbine industry to utilize the LHV when calculating the overall cycle thermal efficiency. A1-3.2 Modified Wobbe Index Range While gas turbines can operate with gases having a very wide range of heating values, the amount of variation that a single specific fuel system can accommodate is much less. Variation in heating value as it affects gas turbine operation is expressed in a term identified as Modified Wobbe Index (Natural Gas, E. N.

Tiratsoo, Scientific Press, Ltd., Beaconsfield, England, 1972). This term is a measurement of volumetric energy and is calculated using the LHV of the fuel, specific gravity of the fuel with respect to air at International Standards Organization (ISO) conditions, and the fuel temperature, as delivered to the gas turbine. The mathematical definition is as follows: Modified Wobbe Index =LHV/(SGgas x Tgas)1/2 This is equivalent to: Modified Wobbe Index =LHV/[(MWgas/28.96) x Tgas]1/2 Where: LHV

= Lower Heating Value of the Gas Fuel (Btu/scf)

SGgas

= Specific Gravity of the Gas Fuel Relative to Air

MWgas

= Molecular Weight of the Gas Fuel

Tgas

= Absolute Temperature of the Gas Fuel (Rankine)

28.96

= Molecular Weight of Dry Air

The allowable Modified Wobbe Index range between 40 and 60 is established to ensure that required fuel nozzle pressure ratios are maintained during all combustion/turbine modes of operation for standard fuel system configurations. An accurate analysis of all gas fuels, along with fuel gas temperature profiles, shall be submitted to GE for proper evaluation.


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A1-3.3 Superheat Requirement

A1-4 Contaminants

The superheat requirement is established to ensure that the fuel gas supplied to the gas turbine is 100 percent free of liquids. Dependent on its constituents, gas entrained liquids could cause degradation of gas fuel nozzles and, for DLE applications, premixed flame flashbacks or reignitions.

Dependent on the type of fuel gas, the geographical location, and the forwarding means, there is the potential for the "raw" gas supply to contain one or more of the following contaminants: 1.

Tar, lampblack, coke

A minimum of 50°F (28°C) of superheat is required and is specified to provide enough margin to compensate for temperature reduction due to pressure drop across the gas fuel control valves. A minimum of 20°F (11°C) of superheat is required at the gas turbine fuel manifold inlet connection.

2.

Water, salt water

3.

Sand, clay

4.

Rust

5.

Iron sulfide

A1-3.4 Gas Constituent Limits

6.

Scrubber oil or liquid

Gas constituents are not specifically limited except to the extent described in paragraph A1-2, Fuel Gas Classification. These limitations are set forth to assure stable combustion through all gas turbine loads and modes of operation. Limitations are more stringent for DLE combustion systems where “premixed” combustion is utilized. A detailed gas analysis shall be furnished to GE for proper evaluation.

7.

Compressor lube oil

8.

Naphthalene

9.

Gas hydrates

A1-3.5 Gas Fuel Supply Pressure Gas fuel supply pressure requirements are dependent on the gas turbine model and combustion design, the fuel gas analysis, and unit specific site conditions. Minimum and maximum supply pressure requirements can be determined by GE for specific applications.

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10. Siloxanes It is critical that the fuel gas is properly conditioned prior to being utilized as gas turbine fuel. This conditioning can be performed using a variety of methods. These include, but are not limited to, media filtration, inertial separation, coalescing, and fuel heating. Trace metal, particulate, and liquid contamination limits are provided in the following paragraphs. These limits are given in parts per million by weight (ppmw) corrected to the actual heating value of the fuel. It is critical that fuel gas conditioning equipment be designed and sized so that these limits are not exceeded.



A1-4.1 Particulates

A1-4.3 Sulfur

Contamination limits for particulates are established to prevent fouling and excessive erosion of hot gas path parts, erosion and plugging of combustion fuel nozzles, and erosion of the gas fuel system control valves. The utilization of gas filtration or inertial separation is required. The filtration level should be a beta ratio of 200 minimum (efficiency of 99.5%) at 5μ or less. The total particulate should not exceed 30 ppmw. GE requires the use of stainless steel piping downstream of this last level of filtration.

Sulfur can sometimes be found in natural gas in the compounds “H2S” and/or “COS”. It is produced with the natural gas. Typically the gas supplier will limit H2S to a concentration of less than approximately 20 ppmv by removing sulfur in a treatment system. Sulfur may also be present in very low concentrations (<100 ppbv) in the form of elemental sulfur vapor.

A1-4.2 Liquids No liquids are allowed in the gas turbine fuel gas supply. Liquids contained in the fuel can result in nuisance and/or hardware damaging conditions. These include rapid excursions in firing temperature and gas turbine load, primary zone reignition and flashback of premixed flames, and when liquids carry over past the combustion system, melting of hot gas path components. When liquids are identified in the gas supply, separation and heating is employed to achieve the required superheat level. Gas at the wellhead is typically produced in a wet saturated condition and is treated to remove water and heavy hydrocarbon liquids. Depending on the degree of treatment and the supply pressure, the gas may be delivered in a dry condition. After pressure reduction it is possible for condensates to form as the gas cools during expansion. The condensates may be either water or hydrocarbons or both. Carry over of lubricating oil from compressor stations is another source of liquids.

There is no specific limit on natural gas fuel sulfur content if the engine is used in an application where both the fuel and environment are free of alkali metals, including sulfur compounds. There are several concerns relative to the levels of sulfur contained in the fuel gas supply. Many of these concerns are not directly related to the gas turbine, but to associated equipment and emissions requirements. These concerns include but are not limited to: A1-4.3.1 Hot Gas Path Corrosion Typically, use of sulfur bearing fuels will not be limited by concerns for corrosion in the turbine hot gas path unless alkali metals are present. Sodium, potassium, and other alkali metals are not normally found in natural gas fuels, but are typically found to be introduced in the compressor inlet air in marine environments, as well as in certain adverse industrial environments. The total amount of sulfur and alkali metals from all sources shall be limited to form the equivalent of 0.6 ppm of alkali metal sulfates in the fuel. Unless sulfur levels are extremely low, alkali levels are usually limiting in determining hot corrosion of hot gas path materials. For low Btu gases, the fuel contribution of alkali metals at the turbine inlet is increased over that for natural gas, and the alkali limit in the fuel is, therefore,


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decreased. The total amount of alkali metals(a) in gas fuels used with engines having marinized (corrosion-resistant) coatings on the high pressure turbine blading shall not exceed 0.2 ppm(b). a. Sodium, potassium, lithium. Experience has shown that sodium is by far the preponderant alkali metal, if any, found in gaseous fuels. b. This limit assumes zero alkali metals in the inlet air or injected water or steam. When actual levels are above zero, the maximum allowable sodium content of the fuel must be reduced in accordance with the following relationship:

ppm sodium inlet air × air/fuel ratio = ppm sodium in water or steam × water or steam ratio fuel

=

ppm sodium in fuel

=

Total fuel equivalence for sodium from all sources not to exceed

______ 0.2 ppm

A1-4.3.2 Heat Recovery Steam Generator Corrosion If heat recovery equipment is used, the concentration of sulfur in the fuel gas must be known so that the appropriate design for the equipment can be specified. Severe corrosion from condensed sulfuric acid results if a heat recovery steam generator (HRSG) has metal temperatures below the sulfuric acid dew point. Contact the HRSG supplier for additional information.

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A1-4.3.3 Selective Catalytic Reduction Deposition Units utilizing ammonia injection downstream of the gas turbine for NOx control can experience the formation of deposits containing ammonium sulfate and bisulfate on low temperature evaporator and economizer tubes. Such deposits are quite acidic and, therefore, corrosive. These deposits, and the corrosion they cause, may also decrease HRSG performance and increase back pressure on the gas turbine. Deposition rates of ammonium sulfate and bisulfate are determined by the sulfur content of the fuel, ammonia content in the exhaust gas, tube temperature, and boiler design. Fuels having sulfur levels above those used as odorants for natural gas should be reported to GE. In addition, the presence of minute quantities of chlorides in the inlet air may result in cracking of AISI 300 series stainless steels in the hot gas path. Contact the selective catalytic reduction (SCR) supplier for additional information. A1-4.3.4 Exhaust Emissions Sulfur burns mostly to sulfur dioxide, but 5 percent to 10 percent oxidizes to sulfur trioxide. The latter can result in sulfate formation, and may be counted as particulate matter in some jurisdictions. The remainder will be discharged as sulfur dioxide. To limit the discharge of acid gas, some localities may restrict the allowable concentration of sulfur in the fuel.



A1-4.3.5 Elemental Sulfur Deposition

A1-5 Definitions

Solid elemental sulfur deposits can occur in gas fuel systems downstream of pressure reducing stations or gas control valves under certain conditions. Power reduction has been observed for DLE applications due to elemental sulfur. These conditions may be present if the gas fuel contains elemental sulfur vapor, even when the concentration of the vapor is a few parts per billion by weight. Concentrations of this magnitude cannot be measured by commercially available instrumentation, and deposition cannot, therefore, be anticipated based on a standard gas analysis. Should deposition take place, fuel heating will be required to maintain the sulfur in vapor phase and avoid deposition. A gas temperature of 130°F (54.4°C) or higher may be required at the inlet to the gas control valves to avoid deposition, depending on the sulfur vapor concentration. The sulfur vapor concentration can be measured by specialized filtering equipment. If required, GE can provide further information on this subject.

A1-5.1 Dew Point

A1-4.4 Siloxanes Siloxanes are sometimes found in nontraditional gas fuels such as obtained from landfills. Siloxanes should be removed with current technology so that the content is as low as possible, but not to exceed 50 ppb by weight in the fuel gas. If the application includes wet NOx controls, the silica limit for the water or steam is reduced to 50 ppb by weight. Gas sampling and analysis is required and should include either an impinger or sorbent collection method and have a laboratory with Gas Chromatography coupled with Mass Spectrometer (GC-MS) capability to analyze the samples collected.

This is the temperature at which the first liquid droplet will form as the gas temperature is reduced. Common liquids found in gas fuel are hydrocarbons, water, and glycol. Each has a separate and measurable dew point. The dew point varies considerably with pressure, and both temperature and pressure must be stated to properly define the gas property. Typically, the hydrocarbon dew point will peak in the 300 to 600 psia (2068 to 4137 kPa) range. A1-5.2 Dry Saturated Condition The gas temperature is at, but not below or above, the dew point temperature. No free liquids are present. A1-5.3 Gas Hydrates Gas hydrates are semisolid materials that can cause deposits that plug instrumentation lines, control valves, and filters. They are formed when free water combines with one or more of the C1 through C4 hydrocarbons. Typically, the formation will take place downstream of a pressure reducing station where the temperature drop is sufficient to cause moisture condensation in a region of high turbulence. Because hydrates can cause major problems in the gas distribution network, the moisture content is usually controlled upstream at a dehydration process station.


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A1-5.4 Gas Hydrate Formation Line

A1-5.7 Superheat

This is similar to the dew point line except the temperature variation with pressure is much less. The hydrate line is always below or at the moisture dew point line, as free water must exist in order for the hydrates to form. Maintaining 50°F (28°C) of superheat above the moisture dew point will eliminate hydrate formation problems.

This is defined as the difference between the gas temperature minus the liquid dew point. The difference is always positive or zero. A negative value implies that the value is being measured at two different states of pressure and temperature and is not valid. A measured gas temperature below the theoretical dew point means that the gas is in a wet saturated state with free liquids present.

A1-5.5 Glycol Glycol is not a natural constituent of natural gas, but is introduced during the dehydration process. Various forms of glycol are used, diethylene and triethylene glycol being two most common. In some cases, glycol is injected into the pipeline as a preservative. In most cases, glycol may only be a problem during commissioning of a new pipeline or if an upset has taken place in an upstream dehydration station.

A1-5.8 Saturation Line This is the same as the dew point line. A1-5.9 Wet Saturated Condition This is a point at which the mixture consists of both vapor and liquids.

A1-5.6 Odorant Odorants are injected into natural and LP gas to make leaks readily detectable. The odorant commonly used for natural gas is tertiary butyl mercaptan, while ethyl mercaptan is used for LP gas.

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MID-TD-0000-2 February 2010

Appendix A2 Liquid Fuel Requirements for GE AeroDerivative Gas Turbines This document lists specifications and describes application guidelines for liquid fuels that can be fired satisfactorily in GE AeroDerivative gas turbines. It is recommended that a complete specification analysis of all liquid fuels proposed for use in GE AeroDerivative gas turbines be reviewed by GE prior to use. A2.1

FUEL SPECIFICATIONS

ASTM D1655 - Standard Specification for Aviation Turbine Fuels (Jet-A, and Jet-A1) ASTM D6615 - Standard Specification for (Jet-B1 Wide-Cut Aviation Fuels ASTM D7566 - Standard Specification for Aviation Turbine Fuels Containing Synthetic Hydrocarbons

Fuels conforming to the following military and industry specifications are acceptable for use in GE gas turbines in industrial and shipboard applications, except as noted below, and provided they also meet the additional criteria described in paragraph A2.2. However, their use should be reviewed against applicable safety and regulatory requirements.

MIL-DTL-16884 - Detail Specification, Naval Distillate (NATO F-76)

D50TF2 - Specification Aviation Turbine Fuel (GEAE)

Gas Turbine Fuel Oils, Grades No. 0-GT1, 2, No. 1-GT, No. 2-GT

ISO 8217 - Petroleum Products-Fuel (Class F) Specification of Marine Fuels (MGO)

ASTM D6751 - Standard Specification for Biodiesel Fuel Blend Stock (B100) for Middle Distillate Fuels

VV-F-800 - Federal Specification, Fuel Oil - Diesel, Grades DF-A, DF-1, and DF-2 (NATO F-54) ASTM D396 - Standard Specification for Fuel Oils, Grades No. 1, 2, 4, and 4 (Light) ASTM D2880 - Standard Specification for

MIL-DTL-5624 - Turbine Fuels, Aviation, Grades JP-41, and JP-5/JP-8 ST (NATO F-40, 44)

Other:

______________________________________

The pure hydrocarbon combustibles [e.g. butane (C4H10) and pentane (C5H12), both normal and iso], are acceptable either alone or in various mixture with other liquid fuels, providing that fuel manifold pressures are sufficient to maintain the fuel in the liquid state. Alternate fuels may be required for starting and low-power operation. Contact GE for specific applications. _____________________________________

1

2

MIL-DTL-83133 - Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F34/F35), and JP-8+100 (NATO F37) ASTM D975 - Standard Specification for Diesel Fuel Oil, Grades 1-D, 2-D, 1-D Low Sulfur, and 2-D Low Sulfur Highly volatile wide-cut fuels (such as MIL-DTL-5624 JP4, ASTM D6615 Jet-B, and ASTM D2880 Grade No. 0-GT) are generally acceptable for industrial, but not shipboard applications.

Liquefied gas fuels, light distillates, and alcohols may have inadequate lubricity, requiring the use of a fuel pump/system specifically designed to handle these types of fuels. See paragraph A2.2.2.

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

A-17


Light distillate fuels2 such as Naphtha (C10 down to C4 hydrocarbons), gasoline (C7 to C5 hydrocarbons) and D2880 Grade No. 0-GT, are acceptable as fuels in GE AeroDerivative gas turbines provided fuel manifold pressures are sufficient to maintain fuel as a liquid, especially in hot climates. Alternative fuels may be necessary for starting the engines and low-power operation. Contact GE for specific applications. Various alcohols2, [e.g. hydroxyl derivatives of hydrocarbons, such as methanol (CH3OH) and ethanol (C2H5OH)], can burn in GE AeroDerivative gas turbines. Contact GE for specific applications. Fuels conforming to ASTM D975 and D396 may contain blends of up to 5% biodiesel per the respective specifications. Biodiesel blends greater than 5% must be reviewed by GE. Any biodiesel in blends must conform to ASTM D6751 and the blend must meet the requirements of this specification. Biodiesel blends have additional requirements described in paragraph A2.4.1. A2.2

PROPERTY REQUIREMENTS

The following requirements supplement and supersede, where there is a conflict, the specification listed in paragraph A2.1. However, if the specification requirement is more restrictive, it applies. Property requirements are listed in Table A2. Contaminant limits apply to fuel samples taken at the gas turbine fuel manifold flange. It cannot be assumed that specification fuel supplied by a refinery still meets those specifications once it is delivered to the gas turbine.

A-18

A2.2.1 Composition The fuel shall consist of hydrocarbon compounds, except where oxygenates are either permitted as part of the specification, such as biodiesel, or agreed to with the user, such as methanol. The fuel composition must be compatible between brands and batches. While there is no specific requirement or limit on the amount of fuel-bound nitrogen (FBN) contained in a liquid fuel, it is recommended that the amount of liquid fuel FBN be understood for those applications that are sensitive to levels of oxides of nitrogen (NOx) in the gas turbine exhaust. FBN is the amount of nitrogen in the fuel that is chemically bound. During the combustion process, the FBN is converted, at least partially, to NOx (called organic NOx) and adds to the total amount of NOx that is contained in the gas turbine exhaust. GE emissions data provided for liquid fuels assumes a FBN content of less than 0.015 percent by weight unless otherwise noted. A2.2.2 Viscosity The viscosity of the fuel as supplied to the inlet connection on the gas turbine shall be a minimum of 0.5 centistokes3 and shall be up to 6.0 centistokes maximum for starting and 12.0 centistokes maximum during operation. The fuel may be heated to meet this requirement.

_______________________________________ 3

Required for adequate GE AeroDerivative gas turbine fuel pump lubrication and to prevent pump cavitation when using light fuels.



(b) The temperature required to remain within maximum fuel viscosity requirements, or 35°F (2°C).

A2.2.3 Wax Wax can be present in fuel oil, specially the distillates with higher pour points. It may be necessary to determine the percent of wax and its melting point and to provide a suitable method to keep the wax dissolved at all times. A2.2.4 Additives The use of any dyes or additives requires approval of GE, unless such additives are specifically approved in the fuel specifications (1.0) or, they conform to MIL-S-53021A. The purchaser may refer to the Qualified Parts List (QPL-53021) for a summary of approved stabilizer additives used in the long-term storage of diesel and distillate fuels. This publication is periodically revised, and is available from the U.S. Government Printing Office. Additives that have been reviewed by GE and considered acceptable are: Biocides: (See supplier documentation for concentration recommendations) NALCO 5309 Biobor JF Kathon FP 1.5 A2.3

ADDITIONAL REQUIREMENTS

The maximum temperature of liquid fuel supplied to the gas turbine should not exceed 150°F (65.6°C). For liquid fuels with high vapor pressure constituents (naphtha, NGL, etc.), the fuel temperature in the manifold should be at least 100°F (55.6°C) below the bubble point temperature of the lightest component at high pressure compressor discharge static pressure (PS3) for Single Annular Combustor (SAC) applications and at least 300°F (167°C) below the bubble point temperature for Dry Low Emissions (DLE) applications. A2.3.2 Filtration The following filtration levels will result in the intent of the fuel specification filtration levels being satisfied. Filtration is most commonly expressed by filter beta ratio (ß) at a specified particle diameter. The standard of beta ratio at a particle size is ß = (total number particle at diameter or greater into filter / particles at diameter or greater through filter). Thus, for a given particle size, efficiency in terms of beta ratio is (ε = [1 − 1/ß] x 100%). Total Particulate 10 mg/gal max (2.64 mg/l) Filtration

A2.3.1 Fuel Temperature Requirements The minimum temperature of liquid fuel supplied to the gas turbine shall be the greater of: (a) 20°F (11°C) above the wax point, (cloud point) temperature of the fuel. or

A2.4

ß = 200 (ε = 99.5%) min @ 5μ or less

FUEL HANDLING

True distillate fuel as refined has low water, dirt, and trace metal contaminant levels that can be maintained with careful transportation, handling, and storage methods. Most contamination occurs during transportation of fuel. Change 1

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

A-19


Since fuel can be contaminated during transportation from the refinery to the site, auxiliary fuel cleanup equipment should be available to restore the fuel quality. Available purification equipment includes centrifuges and electrostatic dehydrators. In addition to potential hot corrosion from salt in the water, water accumulated in the bottom of a storage tank can also cause problems. Microorganisms tend to grow at the water/fuel interface, generating both chemicals corrosive to metals in the fuel system and also slime that can plug fuel filters. In marine applications, shipboard systems that allow recycling fuel from the service tanks through the centrifugal purifiers are recommended. When liquid fuel is supplied by barges or other bulk modes of transportation, it should be pumped directly into raw fuel storage tanks, and must be conditioned/treated before being placed in one of two clean fuel day storage tanks from which gas turbine will be supplied. Redundant, clean day fuel storage tanks are recommended to provide a primary settled fuel supply and to allow tank repair and/or cleaning with minimum downtime. Storage tanks must be constructed of corrosion-resistant materials or appropriately lined to minimize internally formed contaminants. Fuel shall not be transported, stored, or handled in system components containing copper, e.g., ships that have copper heating coils, or storage tanks coated with zinc. Neither copper nor zinc are normally found in refined fuels such as diesel and naphtha, but should they be present, they can cause fuel degradation and additional engine maintenance. No fuel should be used that contains detectable amounts of copper or zinc.

A-20

Duplex, primary strainers (150-200 microns absolute) should be located between the off-loading facility and the raw fuel storage tanks. Duplex, secondary filters (50-100 microns absolute) should be located between the raw fuel storage tanks and the final fuel treatment system. All fuel storage tanks must have inlets at the bottom of the tank. All fuel day storage tanks should be provided with a floating suction. The distance between the inlet and outlet should be maximized. After filling any tank or adding fuel to it, a settling time of 24 hours should be allowed before taking fuel from that tank. Initially, water and sludge should be drained from all storage tanks on a daily basis. After experience is gained with a given fuel and fuel source, the frequency of draining may be adjusted by the customer. A2.4.1 Additional Requirements for Bio-Diesel Fuel •

B100 fuel must be stored at temperatures at least 10°F (5.6°C) above the cloud point. Fuel provided to the gas turbine is to be heated to a 100°F (37.8°C). Failure to maintain these temperatures can cause the fuel to gel resulting in fuel filter and fuel nozzle plugging and fuel pump malfunction.

•

B100 fuel should not be stored for more than 6 months before use.

•

Before using or storing B100 fuel, fuel tanks and the fuel system should be thoroughly cleaned. Failure to do so could cause fuel filter and fuel nozzle plugging and fuel pump malfunction resulting from the cleaning effect of B100 fuel.



•

For DLE applications, the B100 fuel viscosity must not exceed 3cs for starting. This may require fuel temperature greater than 100°F (37.8°C).

B100 will degrade, soften, or seep through some hoses, gaskets, seals, elastomers, glues, and plastics with prolonged exposure. Nitrile rubber compounds, polypropylene, polyvinyl, and tygon materials are particularly vulnerable to B100. Materials such as teflon, viton, fluorinated plastics, and nylon are compatible with B100. It is advisable to set up a monitoring program to visually inspect fuel system equipment once a month for leaks, seeps, and seal decomposition. It would be wise to continue these inspections even after one year, as the experience is still relatively limited with B100. Brass, bronze, cooper, lead, tin, and zinc may accelerate the oxidation of biodiesel fuels and potentially create fuel insolubles (sediments) or gels and salts when reacted with some fuel components. A detailed review of both the gas turbine and the package fuel systems must be completed before long-term use of B100 fuel is initiated. A2.5

FUEL SAMPLING

After the fuel is treated/conditioned, samples should be taken and analyzed at both the inlet and outlet of the fuel treatment system. Fuel exiting the system must meet the fuel specification. This should be confirmed before the fuel is placed in clean fuel day storage tanks. Fuel samples should be taken and analyzed to ensure that the fuel discharged from these tanks and at a practical location at, or just upstream of, the gas turbine fuel manifold flange meets the specification. For all fuel sampling, sufficient samples (a minimum of three) must be taken to assure that a representative sample is obtained. Samples should be taken at different levels in large volume tanks and at equally spaced time intervals during fuel delivery or fuel treatment. To avoid contamination, all samples should be obtained in clean plastic bottles. Fuel samples taken should be analyzed to meet all GE liquid fuel requirements. If fuel samples taken after the above recommendations have been implemented indicate that the fuel system does not provide fuel per the requirements, the customer must change his fuel source or modify the fuel treatment system. The end user is responsible for ensuring that the fuel meets the requirements.

A well thought out fuel sampling protocol will ensure that quality fuel is delivered to the engine. For each delivery, fuel samples should be taken and analyzed at the following locations: •

At the refinery before loading

•

At the port where the fuel is delivered before unloading

•

From the pipeline just upstream of the raw fuel storage tanks as the fuel is being added to the tanks


A-21

MID-TD-0000-2 February 2010 Table A2. Liquid Fuel Property Requirements Property

Limit

Test Method

Ash, %, maximum

0.01

ASTM D482 (IP 4), or ISO 6245

Sulfur, %, maximum

1.0

Vanadium, ppm, maximum Sodium, Potassium, and Lithium, ppm, maximum Lead, ppm, maximum Calcium, ppm, maximum Phosphorus, ppm, maximum

e

Hydrogen content, %, minimum

a

ASTM D129 (IP 336), D4294 (IP 61), D1552, D2622, D1266, D7039, D5453, or ISO 8754

0.2

ASTM D3605, D7111, D6728, or ISO 6891 (V only)

0.2 b, c

ASTM D3605d, D7111, or D6728

1.0

ASTM D3605, D7111, or D6728

2.0

ASTM D3605, D7111, or D6728

2.0 12.7 f, g

ASTM D4951 ASTM D1018, D3701 (IP 338), or D5291

Demulsification, minutes, maximum

20.0

ASTM D1401 and Note 3 therein, or D2711 (if viscosity > 90 cSt)

Particulates, mg/gal, maximum

10.0

ASTM D2276 (IP 216), D5452, or D6217

Water and Sediment, volume %, maximum

0.10h

ASTM D2709, D1796, D6304, or ISO 3734

Flash point, °F, maximum Copper corrosion, maximum Asphaltines, %, maximum Viscosity, cs Minimum Maximum, Starting Maximum, Running Distillation: 10% Point, °F (°C) 50% Point, °F (°C) 90% Point, °F (°C) End Point, Point, °F (°C)

200°Fi (93.3°C)

ASTM D93 (IP 34), D56, D3194, D3828, D3941 (IP 170), or ISO 2719

No. 1j

ASTM D130 (IP 154), D1838, ISO 2160, or ISO 6251

None Detectableg

ASTM D6560 or IP 143 ASTM D445

0.5 6.0 12.0 ASTM D86 Report Report 675 (357)k 725 (385)k

Carbon residue, %, maximum (100% sample)

1.0

ASTM D524 or IP 4262

Carbon residue, %, maximum (10% Ramsbottoms)

0.25

ASTM D524 or IP 4262

Specific Gravity

Report

ASTM D287, D1298, D1480, or D4052

Cloud Point

Report

ASTM 2500

Lower Heating Value (LHV) BTU/LB

Report

ASTM D240 or D4809

Nitrogen (Fuel Bound Nitrogen), %

Report

ASTM D5291, D4629, D5762, or D3228

ASTM - ASTM International ISO - International Organization for Standardization IP - Institute of Petroleum UK When an IPxxx in parentheses follows immediately after an ASTM Dxxx, it is the identical method. Example ASTM D130 (IP 154). If the IPxxx is listed without Parentheses it is not identical, but is an acceptable alternative method.

A-22


MID-TD-0000-2 February 2010 Table A1. Liquid Fuel Property Requirements (Continued) Notes: a. Fuels with a higher sulfur content can be burned. Impact on HSRI (Hot Section Repair Interval) will be dependent upon alkali metals present in the fuel, inlet air, and injected water, and upon engine operating temperature. Consult GE for review of higher sulfur fuels. b. This limit is considered to include all alkali metals, e.g., potassium and lithium as well as sodium. Experience, however, has shown that sodium is generally the predominant alkali metal. This limit also assumes zero alkali metals in the inlet air or injected water or steam. When actual levels are above zero, the maximum allowable sodium content of the fuel must be reduced in accordance with the following relationship: ppm Na in Inlet Air x Air/Fuel Ratio + ppm Na in Water or Steam x Water or Steam/Fuel Ratio + ppm Na in Fuel Total fuel equivalence for sodium from all sources not to exceed 0.2 ppm. c. For nonmarinized engines (except for LM6000), the total amount of alkali metals from all sources shall not exceed 0.1 ppm. d. To achieve the level of sensitivity for detection of sodium to the level required, an atomic absorption spectrometer or a rotating disc spectrometer may be necessary. e. Phosporus testing applies to Bio-Diesel blends only. f.

Care must be taken with the more viscous fuels to ensure that the minimum hydrogen content is met.

g. Fuels with Hydrogen content lower than 12.7% have been approved for use in certain applications with specific restrictions. These fuels require a development test program for the applicable engine model before approval would be considered. Asphaltene testing applies only to such fuels. In general, fuels with Hydrogen content less than 10% have not been shown to be acceptable. h. For marine gas turbines using a hydromechanical main fuel control, the limit is 40 ppm. i.

Legal limits and applicable safety regulations must be met; however, it should be noted that use of fuels having a flash point in excess of 200°F (93.3°C) may result in unsatisfactory starting characteristics. Blending for enhancement of spark ignition or use of alternate fuels may be required for starting.

j.

Copper corrosion test conditions are 2 hours at 212°F (100°C).

k. LM6000 SAC models may not operate without water injection above 15MW power, if the distillation end point temperature is above 675°F (357°C).

Change 1

A-23/(A-24 Blank)

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


GEK 105054 Volume I

APPENDIX A3 Water Purity Specification for NOx Suppression in GE Aircraft Derivative Gas Turbines in Industrial Applications This specification establishes the requirements for purified water for NOx suppression in gas turbine engines. For the purpose of this specification, the following definition shall apply: NOx Suppression Water - Water introduced into the engine combustor for the purpose of suppressing the oxides of nitrogen (NOx) in the engine exhaust gases. A3.1

ASTM D1888 Tests for Particulate and Dissolved Matter in Water ASTM D3370 A3.2

ASTM D512

Tests for Chloride Ion in Water and Waste

ASTM D516

Tests for Sulfate Ion in Water and Waste

ASTM D859

Tests for Silica in Water and Waste

ASTM D1125 Tests for Electrical Conductivity and Resistivity of Water ASTM D1192 Equipment for Sampling Water and Steam ASTM D1293 Tests for pH of Water ASTM D1428 Tests for Sodium and Potassium in Water and Water-Formed Deposits by Flame Photometry

REQUIREMENTS

a.

Sampling Requirements. The sampling shall be in accordance with ASTM D3370. A minimum of one gallon or four liters shall be supplied.

b.

Chemical Requirements. The water shall meet the following requirements when tested in accordance with the designated test method:

c.

Filtration Requirements. The water shall contain no particles larger than 20 microns absolute.

APPLICABLE DOCUMENTS

American Society of Testing and Materials Publications. Available from American Society for Testing and Materials, Customer Service, 100 Bar Harbor Drive, West Conshohocken, PA 19428-2959.

Practices for Sampling Water

Limit Total matter, ppm, max.

Test Method

5

ASTM D1888

Dissolved matter, 3 ppm, max.

ASTM D1888

pH1

6.0-8.0

ASTM D1293

Conductivity, micromhos/cm at 25°C, max.1

0.5-1.0

ASTM D1125

Sodium + potassium, ppm, max.

0.1

ASTM D1428

A-25 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume I

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Limit

Test Method

Silicon dioxide, 0.1 ppm, max.

ASTM D859

Chlorides, ppm, 0.5 max.

ASTM D512

Sulfates, ppm, max.

ASTM D516

b.

0.5

pH and/or conductivity shall be measured when water is free of carbon dioxide.

Total Conductivity [Cation + Anion @ 77°F (25°C)].

STEAM INJECTION PURITY SPECIFICATION

Abnormal: As high as 2.0 micromho/cm (5 percent of operating time) c.

Total Solids. (1)

The maximum total solids is dependent upon the maximum steam to fuel ratio at which the engine is to operate in the specific application. The value is determined from figure 2. Maximum contaminant size shall not exceed 20 microns.

(2)

There is no differentiation between types of solids as long as other limitations of this paragraph are met.

(3)

Calculate maximum steam to fuel ratio by dividing the total high pressure steam (fuel nozzles plus CDP) by fuel flow (WF36) for site operating conditions. Where steam flow may vary widely, the operating condition with the highest steam to fuel ratio should be used.

(4)

From the curve, determine the Total Solids Permissible and apply this limit to the high pressure steam supplied to the gas turbine.

A3.3.1 Steam Purity/Contamination Limit. a.

Sodium + Potassium (Na + K). (1)

(2)

By this equation, if there was zeroNa + K in the air and fuel, the maximum allowed in the steam in PPB would be 200 divided by S/F.

Normal: 0.5-1.5 micromho/cm (95 percent of operating time) NOTE

A3.3

(3)

The maximum amount of Na + K allowed in the steam injected into M&I engine depends upon the total Na + K contamination from all sources; i.e., from the fuel, air, and steam. Therefore, the maximum Na + K allowed in the steam is determined from the equation:

(PPBFuel) + (PPBAir)A/F + (PPB Steam) S/F=200 PPB Where: PPBFuel

= Parts Per Billion Na + K in Fuel

PPBAir

= Parts Per Billion Na + K in Air d.

PPBSteam

= Parts Per Billion Na + K in Steam

A/F

= Air/Fuel Ratio (Wt. Basis)

S/F

= Steam/Fuel Ratio (Wt. Basis)

Steam Sampling. Steam samples should be taken in accordance with ASTM 1066 procedures.



GEK 105054 Volume I

APPENDIX A4 Compressor Cleaning Water Purity Specification for GE Aircraft Derivative Gas Turbines in Industrial Applications This specification establishes the requirements for purified water for use in cleaning the compressor of gas turbine engines where the intent is to restore performance by removing deposits from compressor components. The water quality defined in this specification applies to water used in both on-line compressor cleaning and crank-soak compressor cleaning.

Cleaning Solution - A solution or emulsion of liquid detergent and water or a water and antifreeze mixture for direct engine application. The recommended dilution of liquid detergent and water shall be specified by the liquid detergent manufacturer.

For the purpose of this specification, the following definitions shall apply:

The following documents shall form a part of this specification to the extent defined herein. Unless an issue is stipulated, the latest revision shall apply.

On-line Compressor Cleaning - A method of removing the buildup of deposits on compressor components while the engine is operating. On-line cleaning is accomplished by spraying cleaning solution into the inlet while the engine is operating. Crank-Soak Compressor Cleaning - A method of removing the buildup of deposits on compressor components while the engine is motored by the starter. Crank-soak cleaning is accomplished by spraying cleaning solution into the inlet while the engine is operating unfired at crank speed. Liquid Detergent - A concentrated solution of water-soluble surface active agents and emulsifiable solvents.

A4.1


Available from American Society for Testing and Materials, Customer Service, 100 Bar Harbor Drive, West Conshohocken, PA 19428-2959. ASTM D1192 Equipment for Sampling Water and Steam ASTM D1293 Tests for pH of Water ASTM D1428 Tests for Sodium and Potassium in Water and Water-Formed Deposits by Flame Photometry ASTM D1888 Tests for Particulate and Dissolved Matter in Water ASTM D3370 Practices for Sampling Water


GEK 105054 Volume I


A4.2 SAMPLING REQUIREMENTS

A4.4

Sampling shall be in accordance with ASTM D1192 and ASTM D3370. A minimum sample of one gallon or four liters shall be supplied.

The water shall contain no particles larger than 100 micrometers absolute.

A4.3

FILTRATION REQUIREMENTS

CHEMICAL REQUIREMENTS

The water shall meet the following requirements when tested in accordance with the designated test method below: Property Requirements

Limit

ASTM Test Method

Total matter, max

100 ppm

D1888

pH

6.5 - 8.5

D1293

Sodium + potassium, max

25 ppm

D1428



GEK 105054 Volume I

APPENDIX A5 Liquid Detergent for Compressor Cleaning for GE Aircraft Derivative Gas Turbines in Industrial Applications This specification establishes the requirements for liquid detergents used to prepare solutions for cleaning the compressors of gas turbine engines, where the intent is to restore performance by removing deposits on compressor components. Such deposits include salt, soils, and oils that may be ingested from the atmosphere.

ARP 1795

Stress-Corrosion of Titanium Alloys, Effect of Cleaning Agents on Aircraft Engine Materials

ASTM D88

Standard Test Method For Saybolt Viscosity

The cleaning process shall be carried out by spraying the cleaning solution into the bellmouth of the engine while the engine is running at power (on-line cleaning) or while the engine is being cranked (crank-soak cleaning).

A5.2.1

For the purposes of this specification, the following definitions shall apply: Liquid Detergent - A concentrated solution of water-soluble surface active agents and emulsifiable solvents. Cleaning Solution - A solution or emulsion of liquid detergent in water or water and antifreeze mixture for direct engine application. Recommended dilution of detergent and water shall be determined by the detergent manufacturer. A5.1


The following documents shall form a part of this specification to the extent defined herein. Unless an issue is stipulated, the latest revision shall apply. AMS 1424

Deicing/Anti-icing Fluid, Aircraft (Newtonian - SAE Type I)

A5.2 DETERGENT PROPERTIES Composition

The chemical composition of the detergent is not limited, other than as specified herein. A5.2.2

Biodegradability

Use of detergent/cleaning solution shall conform to local regulations for water pollution. Biodegradable ingredients are recommended. A5.2.3

Toxicity

Use of the liquid detergent/cleaning solution shall conform to local regulations for industrial hygiene and air pollution. Use of nontoxic ingredients is recommended. A5.2.4 Health and Safety Information The liquid detergent manufacturer shall make available health and safety information for the liquid detergent as required by applicable local, state, and federal regulations. A5.2.5

Solids

The liquid detergent shall contain no particles larger than 20 micrometers. A5.2.6 Physical and Chemical Properties The liquid detergent shall meet the following test requirements: A-29


GEK 105054 Volume I A5.3

TEST REQUIREMENTS

Requirements are defined for liquid detergents and for cleaning solutions. A5.3.1 A5.3.1.1

Liquid Detergent Residue or Ash Content

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines A5.3.1.4

Hard Water Compatibility

The liquid detergent shall show no separation or layering when mixed with synthetic hard water prepared in accordance with A5.4.2. A5.3.1.5

Acid and Alkali Acceptance

Residue or ash content shall not exceed 0.01 percent when tested in accordance with A5.4.1.

The liquid detergent shall show no separation, layering, or precipitation when tested in acidic or alkali media in accordance with A5.4.3.

A5.3.1.2

A5.3.1.6

Low-Temperature Stability

Salt Water Tolerance

The liquid detergent shall show no evidence of separation of component parts when maintained at 37 to 43°F (2.8 to 6.1°C). It is highly desirable, although not mandatory, that the fluid shall remain liquid below 32°F (0°C).

The liquid detergent shall show no separation or gelling when mixed with 3.5 percent salt water in accordance with A5.4.4.

A5.3.1.3 Cold Weather Solution Compatibility

The liquid detergent shall have a viscosity of 50 - 200 SUS at 77°F (25.0°C) when tested in accordance with ASTM D88.

The liquid detergent shall show no separation, layering, or precipitation when mixed to the liquid detergent manufacturer's recommended dilution in one or more of the following antifreeze solutions after 2 hours at 7 to 13°F (-13.9 to -10.6°C):

•

Isopropyl alcohol

•

Monopropylene glycol (PG)

A5.3.1.7

A5.3.1.8

Viscosity

Acidity and Alkalinity (pH)

The pH of the liquid detergent as received shall be from 6.5 - 8.5 when measured with a suitable pH meter employing a glass electrode.

See A5.6 for more information regarding liquid detergent and antifreeze mixtures.



A5.3.2

Cleaning Solution

A5.3.2.1

A5.4

TEST METHODS

A5.4.1

Corrosive Elements

Maximum levels of elements in the cleaning solution which may promote various types of corrosion, shall be no greater than as shown in Table A3 when analyzed by methods in A5.4.5. Table A3 Corrosives Level Total Alkali Metals (Sodium + Potassium + Lithium, etc.)

25 ppm max

Magnesium + Calcium

5.0 ppm

Vanadium

0.1 ppm

Lead

0.1 ppm

Tin + Copper

10 ppm

Sulfur

50 ppm

Chlorine

40 ppm

A5.3.2.2

GEK 105054 Volume I

pH

The pH of the cleaning solution shall be from 6.5 - 8.5 when measured with a suitable pH meter employing a glass electrode.

Residue or Ash Content

Weigh 9.9 - 10.1 grams of sample liquid detergent in a weighed 30 ml porcelain crucible. Heat gently to volatilize any water or solvents. Crucible may be placed in air oven at 217 to 224°F (102.7 to 106.6°C) for 24 hours, followed by 460 to 468°F (237.7 to 242.2°C) for 24 hours to ensure all volatile matter is evaporated. Finally, ignite contents over Bunsen burner, first at low temperature under good oxidizing conditions until all ignitable material is consumed, then place a crucible in a muffle furnace at 1,904 to 2,012°F (1,039.9 to 1,099.9°C) for 2 hours, cool in a desiccator, and weigh. Percent residue or ash = (100 x A) / W Where: A5.4.2

A = grams of residue W = grams of sample Hard Water Compatibility

A5.4.2.1 Preparation of Synthetic Hard Water A hard water solution is prepared by dissolving the following in one liter of just boiled and cooled distilled water: a.

0.195 - 0.205 gram, calcium acetate, reagent grade Ca(C²H³O²)²•H²O

b.

0.145 - 0.155 gram, magnesium sulfate, reagent grade MgSO4•7H2O

A5.4.2.2

Hard Water Test

Add 5 ml of liquid detergent to a clean 50 ml cylinder. Add 45 ml of synthetic hard water and mix well. Examine the solution for compatibility after 16 hours at 72 to 82°F (22.2 to 27.7°C).


GEK 105054 Volume I A5.4.3


Acid and Alkali Acceptance

The liquid detergent shall be mixed with distilled water in accordance with the liquid detergent manufacturer's recommended dilution. To 50 ml of the solution, add 1 ml of 75 percent phosphoric acid. To another 50 ml of the solution, add 5 ml of 75 percent phosphoric acid. To another 50 ml of the solution, add 1 ml of 50 percent potassium hydroxide. Let all three mixtures stand for one hour at 72 to 82°F (22.2 to 27.8°C), and then examine for acid or alkali acceptance. A5.4.4

Salt Water Tolerance

Prepare a 3.5 percent by weight solution of sodium chloride in distilled water. Add 15 ml of salt solution to 35 ml of liquid detergent and let stand for 1 hour at 72 to 82°F (22.2 to 27.8°C). Examine for salt water tolerance.

A5.4.5

Elemental Content

Elemental content shall be determined using the following methods: Element

Method

Sulfur, Phosphorus

Inductively-Coupled Plasma Spectroscopy Atomic Emission Spectroscopy (ICP-AES)

Chlorine

Microcoulometric filtration

Sodium, Potassium

Atomic Absorption (AA)

Other metals

ICP-AES or AA

A5.5 A5.5.1

COMPATIBILITY Engine Materials

Use of the detergent gas turbine cleaner shall not have adverse effects on engine system materials such as titanium stress corrosion, hot corrosion of turbine components, or damage to lubrication system components. A5.5.2

Titanium Stress Corrosion

A titanium stress corrosion test in accordance with ARP 1795 or equivalent may be run on the liquid detergent at the discretion of GE/M&IE. A5.6

COLD WEATHER USAGE

In cold weather, liquid detergent must be added to antifreeze mixture rather than to water alone. At present, the only acceptable antifreeze solutions are:

•

Isopropyl alcohol

•

Monopropylene glycol (PG)

Monopropylene glycol (PG) must be per AMS 1424 and may be used down to 20°F (-6.7°C). Antifreeze mixtures are shown in Table A4. The liquid detergent manufacturer must specify which, if any, of the antifreeze specified above (also specified in A5.3.1.3) is not compatible with the liquid detergent. Use of nonisopropyl alcohol, ethylene glycol, or additives containing chlorine, sodium, or potassium is not permitted since they may attack titanium and other metals. It is extremely important that the liquid detergent and antifreeze solution be a homogeneous mixture when sprayed into the bellmouth of the gas turbine. If after 2 hours, the liquid detergent and antifreeze solution separates (see A5.3.1.3), agitation of the mixture in the wash water tank is permissible. However, the liquid detergent manufacturer shall specify that agitation is required.



GEK 105054 Volume I

Table A4 Water-Wash Antifreeze Mixtures Compressor Washing Antifreeze Mixtures Outside Air Temperature, °F (°C)

Monopropylene Glycol (PG) % Vol

+20 to +50 (-7 to +10)

H2O % Vol

Isopropyl Alcohol % Vol

H2O

21

79

22

78

+10 to +20 (-12 to -7)

N/A

N/A

34

66

0 to +10 (-18 to -12)

N/A

N/A

47

53

-10 to 0 (-23 to -18)

N/A

N/A

72

28

-20 to -10 (-29 to -23)

N/A

N/A

88

12

-30 to -20 (-34 to -29)

N/A

N/A

97

3

% Vol

Compressor Rinsing Antifreeze Mixtures +20 to +50 (-7 to +10)

14

86

18

82

+10 to +20 (-12 to -7)

N/A

N/A

27

73

0 to +10 (-18 to -12)

N/A

N/A

39

61

-10 to 0 (-23 to -18)

N/A

N/A

58

42

-20 to -10 (-29 to -23)

N/A

N/A

70

30

-30 to -20 (-34 to -29)

N/A

N/A

77

23



GEK 105054 Volume I

APPENDIX A6 Specification for Lubricating Oil for GE Aircraft Derivative Gas Turbines This document provides the requirements and application guidelines for selection of lubricating oils that can be satisfactorily used in GE M&IE applications. It is recommended that the selected lubricating oil be reviewed with GE M&IE prior to use. A6.1

OIL SPECIFICATIONS

Oils conforming to the US Department of Defense (DoD) Specifications listed in Section A6.2.1 are acceptable for use in GE Aircraft Derivative gas turbines, provided they are listed on the Qualified Product List (QPL) for the Specification. Commercially available synthetic base lubricating oils are acceptable for use in GE aircraft derivative gas turbines provided they are listed in Section A6.4. Such oils largely conform to the primary requirements of the oils in Section A6.2.1, but certain variations have been approved. Such oils have been qualified by the supplier to meet the requirements of the Specification. A6.2


The following documents form a part of this specification to the extent defined herein. Unless a particular issue is stipulated, the latest revision shall apply. A6.2.1

U.S. DoD Specifications

MIL-L-23699 - Lubricating Oil, Aircraft Turbine Engines, Synthetic Base

A6.2.2 American Society of Testing and Materials The following documents are available from American Society for Testing and Materials, Customer Service, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959: ASTM D2532

Low Temperature Viscosity

ASTM D97

Pour Point

ASTM D445

Kinetic Viscosity

A6.3

REQUIREMENTS

Lubricating oil shall conform to MIL-L-23699; however, exceptions to the following requirements will be considered:

•

Low-temperature viscosity when tested per ASTM D2532

•

Pour point when tested per ASTM D97

•

Viscosity at 104°F (40°C) and 212°F (100°C) when tested per ASTM D445

•

Base stock composition

Specific variations to MIL-L-23699 shall be provided by the oil supplier, along with performance difference impacts, for review by GE M&IE.

MIL-L-7808 - Lubricating Oil, Aircraft Turbine Engines, Synthetic Base, Type I


GEK 105054 Volume I A6.3.1

Material Compatibility

The lubricating oil shall be compatible with the same elastomer seal and metallic materials as the MIL-L-23699 compliant lubricating oils. The lubricating oil shall be mixable with MIL-L-23699 or MIL-L-7808 compliant oil in a ratio up to 5 percent of either, without adversely affecting the property integrity of the majority, or operating oil. Mixing of oils is not intended but will result due to engine location changes. A6.4

QUALIFICATION

Lubricating oil shall be considered qualified and acceptable for use in GE M&I aircraft derivative gas turbines after demonstrating conformance to the requirements and after being listed in paragraph A6.4.4. The qualification program shall be carried out by the oil supplier in conjunction with a sponsoring gas turbine owner/operator. GE M&I’s participation will be limited to technical consultation, review, and final approval. A6.4.1

Performance Tests

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines A6.4.2

Service Evaluation Tests

The oil shall undergo service evaluation testing in a GE M&IE LM series gas turbine application(s). The sponsoring operator will accept total responsibility for all results related to operating with the candidate lubricating oil. The service evaluation engine shall have a known hardware condition baseline, based on depot inspection or new delivery, immediately prior to the service evaluation test. Service evaluation testing shall be conducted on a minimum of three LM series gas turbines, each accumulating at least 8,000 operating hours at a baseload operating site prior to inspection. During operation, periodic oil samples shall be tested and trended for physical and chemical property changes. Inspection shall be performed at an authorized depot and be in accordance with the applicable repair manual. Inspection shall focus on the oil-wetted parts, including the bearings, gears, elastomer seals, sump oil seals, actuators, and lube/hydraulic pumps. GE M&I will be permitted to witness any of the inspections, at the discretion of GE.

The oil supplier shall conduct tests in accordance with MIL-L-23699 and compare the results with the requirements stated therein. All results, particularly variations to MIL-L-23699 requirements, shall be reviewed with GE M&I prior to service evaluation testing. The material presented for review shall include, as a minimum, the following:

The oil supplier and/or operator shall prepare and submit a Final Qualification Report to GE M&I. The report shall include, as a minimum:

•

Oil brand description including the complete formulation

•

Physical chemical properties and variations to MIL-L-23699

•

Certified physical, chemical, and performance test results

•

Expected impact to operating systems due to property variations

•

Material safety data sheets

•

Material compatibility lists and test results

•

Service evaluation test history including all significant operational and maintenance events.

•

Oil-coking test results

•

Final depot engine inspection results

A6.4.3

Qualification Report



Upon review and approval of the Final Qualification Report by GE M&IE, the candidate oil will be included on the approved oils list. Formulation changes affecting any approved performance characteristics must be reviewed with GE M&IE to assess potential impact on qualification results.

GEK 105054 Volume I

A6.4.4

Approved Lubricating Oils

In addition to those listed on QPL-23699 and QPL-7808 (Qualified Products List), the following lubricating oils are approved for use in GE M&I gas turbines and gas generators: 1. None at this time.



GEK 105054 Volume I Addendum A

}}}

ADDENDUM INDUSTRIAL AERODERIVATIVE GAS TURBINE MODEL LM2500-PK-MG



GEK 105054 Volume I Addendum A

TABLE OF CONTENTS

Paragraph

Title

Page

1.

INTRODUCTION ............................................................................................ 4

2.

REFERENCE DATA ........................................................................................ 4

2.1

Equipment......................................................................................................... 4

2.2

Performance Rating .......................................................................................... 4

3.

SERVICE REQUIREMENTS .......................................................................... 4

3.1

Natural Gas....................................................................................................... 4

3.2

Water Wash Fluids ........................................................................................... 4

4.

INTERFACE CONNECTIONS........................................................................ 5

4.1

Optional Equipment ......................................................................................... 5

4.2

Optional Hardware Kits ................................................................................... 5


GEK 105054 Volume I Addendum A 1.

INTRODUCTION

The information contained herein describes the LM2500-PK-MG model gas turbine basic configuration and control system differences. In addition, the coverage of reference data, servicing requirements, and optional hardware kits are included. 2. 2.1

REFERENCE DATA

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Natural Gas: See Appendix A1. Refer to the Packager’s documentation for performance data under installed site conditions and control limits. 3. 3.1

The required supply pressure to the natural gas manifolds interface flange is determined by the required maximum power output, fuel composition, and fuel temperature. Consult with the packager for determination of the required natural gas supply pressure at the packager’s interface at site conditions.

b.

The temperature of the natural gas fuel supply at the fuel manifold interface must be 20°F (11°C) greater than the saturated vapor temperature of the gas at the delivered pressure. The temperature of the natural gas fuel should not exceed 300°F (148.8°C) at the gas manifold interface flange.

c.

The natural gas fuel requirements are provided in Volume 1, Appendix A1.

Equipment

Performance Rating

The nominal average rated performance of the LM2500-PK-MG gas turbine in the new and clean condition is as follow: Shaft Horsepower: 39,000 bhp (29,082 kW) Heat Rate: 6,495 BTU/HP-Hr (9,188 kJ/kW-Hr) Inlet Air Temperature: 59°F (15°C) Altitude: Sea Level Inlet Losses: 0 in. H²0 Exhaust Losses: 0 in. H²0 Relative Humidity: 60% Compressor Bleed Extraction: 0 Accessory Power Extraction: 0 Power Turbine Speed: 3,600 rpm Emission Abatement: Unabated

Natural Gas

a.

The LM2500-PK-MG model is a marinized, natural gas fueled, gas turbine. The natural gas fuel system consists of a fuel manifold and 30 removable fuel nozzles. A fuel schematic is shown in Volume 1, Chapter 5. 2.2

SERVICE REQUIREMENTS

3.2

Water Wash Fluids

Compressor cleaning is accomplished using water conforming to, Volume 1, Appendix A2 . Detergents used to assist in cleaning shall conform to Volume 1, Appendix A3.



4.

INTERFACE CONNECTIONS

Gas turbine instrument and supply connections, as-well-as standard and optional equipment, are defined in Volume 1, Chapter 2.

GEK 105054 Volume I Addendum A 4.1

Optional Equipment

Consult with the GE M&I Customer Service Manager for a list of available optional equipment unique to the LM2500-PK-MG model. 4.2

Optional Hardware Kits

Refer to Volume II, WP 101 00, for a detailed list of optional kits for the LM2500-PK-MG gas turbine model.



GEK 105054 Volume I Addendum B

ADDENDUM INDUSTRIAL AERODERIVATIVE GAS TURBINE MODEL LM2500-PK-MGS

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


Paragraph

GEK 105054 Volume I Addendum B Title

Page

1.

INTRODUCTION ............................................................................................ 4

2.

REFERENCE DATA ....................................................................................... 4

2.1

Equipment........................................................................................................ 4

2.2

Performance Rating......................................................................................... 4

3.

SERVICE REQUIREMENTS ......................................................................... 5

3.1

Natural Gas...................................................................................................... 5

3.2

Steam Injection System................................................................................... 5

3.2.1

Steam Flow, Pressure, and Temperature Requirements .............................. 5

3.3

High Pressure Steam System ......................................................................... 6

3.4

Steam Scheduling ............................................................................................ 6

4.

OPTIONAL HARDWARE KITS ..................................................................... 7

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

GEK 105054 Volume I Addendum B 1.

INTRODUCTION

The information contained herein describes the LM2500-PK-MGS model gas turbine basic configuration and control system differences. In addition, the coverage of reference data, servicing requirements, optional hardware kits, and unique operating instructions for the LM2500-PK-MGS model are included. 2. 2.1 a.

b.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines c.

2.2

Performance Rating NOTE

REFERENCE DATA Equipment The LM2500-PK-MGS model is a marinized, natural gas fueled, gas turbine which is capable of accepting steam produced by a heat recovery steam generator (HRSG) in the gas turbine exhaust system. Benefits resulting from injection of steam into the gas generator are increased output horsepower, improved thermal efficiency, and suppression of the oxides of nitrogen (NOx) in the engine exhaust gases. A fuel schematic is shown in Volume1, Chapter 5. Steam is injected into the high pressure section of the engine by means of an engine-mounted fuel nozzle steam manifold. Steam flow in the manifold system is regulated by steam metering valves, with the required flow levels based on optimization of emissions suppression and available steam.

Steam injected into the fuel nozzle steam manifold is directed into the combustor primary zone through a special steam and gas fuel nozzle. The premix nozzles use a chamber in the nozzle body to mix the steam and gas streams.

a.

•

Ratings published in this manual apply to the gas turbine. The driven unit ratings/limits may be lower in some cases and shall take precedence over the gas turbine manual limits.

•

Performance data with steam injection is available from the General Electric Company. Purchaser’s request should include site conditions, fuel heating value and chemical composition, steam quantities, steam temperature, and steam supply pressure at the entrance to the steam manifolds. The nominal, average-rated performance of the LM2500-PK-MGS gas turbine in the new and clean condition is as follows:

Shaft Horsepower: 39,640 bhp (29,560 kW) Heat Rate: 6,309 BTU/HP-Hr (8,925 kJ/kW-Hr) Inlet Air Temperature: 59°F (14.9°C) Altitude: Sea Level Inlet Losses: 0 in. H²0 Exhaust Losses: 0 in. H²0 Relative Humidity: 60% Compressor Bleed Extraction: 0 Accessory Power Extraction: 0 Power Turbine Speed: 3,600 rpm Emission Abatement: Steam Injection to 25 ppm NOx



Natural Gas: See Volume 1, Appendix A1. Refer to the Packager’s documentation for performance data under installed site conditions and control limits. Power Turbine Inlet Gas Temperature, T5.4 max.: See packager’s manual for site rating and control limits. 3. 3.1 a.

b.

SERVICE REQUIREMENTS Natural Gas The required supply pressure to the natural gas manifolds interface flange is determined by the required maximum power output, fuel composition, and fuel temperature. Consult with the packager for determination of the required natural gas supply pressure at the packager’s interface at site conditions. The temperature of the natural gas fuel supply at the fuel manifold interface must be 20°F (11°C) greater than the saturated vapor temperature of the gas at the delivered pressure. The temperature of the natural gas fuel should not exceed 300°F (148.8°C) at the gas manifold interface flange. Based on consideration of control system components however, it is recommended that the maximum gas supply temperature be limited to 150°F (65.5°C). If the supply temperature of the gas is not repeatable on a day-to-day basis, it may be necessary to change the control system starting fuel adjustment or to adjust the supply pressure to the gas turbine to maintain a constant BTU/ft supply.

GEK 105054 Volume I Addendum B The maximum fuel flow required, assuming a lower heating value of 19,000 BTU/ lb., is 13,500 pph (6,123 kg/hr) for the LM2500-PK-MGS model gas turbine. c.

The natural gas fuel requirements are provided in Volume 1, Appendix A1.

3.2

Steam Injection System

3.2.1 Steam Flow, Pressure, and Temperature Requirements NOTE Refer to Volume 1, Appendix A6, for steam purity specifications. a.

The high pressure gas/steam injection systems includes a steam metering system to control flow to the fuel nozzles. Flow meters measure the flow through the gas and steam metering valves.

b.

The minimum permissible steam temperature at the inlet to the steam manifold is 50°F (28°C) above saturation.

c.

The maximum permissible steam flow into the fuel nozzle and steam manifold is a function of compressor discharge pressure (PS3).

d.

Whenever high pressure steam is injected into the engine, a minimum flow should be provided to the fuel nozzle steam as described in Table 7-7, Chapter 7.

e.

Premix type fuel systems do not require a preheating method for the steam manifold.

f.

Levels of steam contamination must not exceed those defined in Volume 1, Appendix A6.


GEK 105054 Volume I Addendum B 3.3 a.

High Pressure Steam System It is recommended that steam be scheduled as a function of high pressure compressor discharge static pressure (PS3). Limits on high pressure steam flow versus PS3 are continued in the applicable control specification. Consult packager.

b.

Steam flow shall be initiated only after the engine is stabilized at power.

c.

Liquid water shall be prevented from entering the steam manifold during engine operation. Before initiating steam flow, steam supply lines and components shall be purged (preheated) until their metal temperatures are a least 50°F (28°C) above the saturated steam temperature. Precautions must be exercised to ensure that any steam condensation in the fuel nozzle steam supply lines during engine operation is continuously being removed through the bleed drain systems.

d.

The steam supply system shall be protected by check valves and positive shutoff valves to prevent fuel gas or hot engine gases from back flowing into the Purchaser supplied steam system when steam is not being used for engine operation.

e.

The steam system volume downstream of the metering valve affects transient operation. It is recommended that the piping volume from the metering valve to the steam manifold be no greater than 1,272 in.³(0.021 m³).

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines f.

Metering valve in the steam system must have 100 percent travel shutdown time of less than 100 milliseconds (same as gas fuel shutdown valve). The steam shutoff valves shall close within 1.0 second.

g.

The gas turbine does not require any particular minimum steam flow through the fuel nozzle steam manifold; however consideration must be given to the system external to the engine with respect to line lengths, volumes, pipe, lagging, cooling air flow over the lines, etc., to prevent condensation from developing due to an inadequate superheat and/or insufficient flow through the external pipes and components

3.4

Steam Scheduling

a.

Steady state steam flow is scheduled as a function of compressor discharge static pressure (PS3). The steam flow operational limits are provided in the control specification.

b.

In all emergency conditions requiring immediate reduction in power level, it will be necessary to close steam metering valve at least as rapidly as the fuel shutoff valves. This rapid shutdown of the steam system avoids a high steam to fuel ratio in the combustor during rapid transients and, coupled with the specified downstream volumes, will reduce the probability of combustor flameout.



c.

The steam control system shall remove all water and saturated steam and raise the pipe or component metal temperature to at least 50°F (28°C) above steam saturation temperature prior to initiation of steam injection into the engine manifolds. When the preheating valves are open, the steam metering valves shall be closed. When steam temperature at the preheating valves is 50°F (28°C) or above saturation temperature, the control then signals preheating valves to close and provides a permissive signal for steam metering valves to open. The steam metering valves must be opened in 30 seconds, if not, the preheating cycle must be reinitiated.

GEK 105054 Volume I Addendum B 4.

OPTIONAL HARDWARE KITS

Refer to Volume II, WP 101 00, for a detailed list of optional kits for the LM2500-PK-MGS gas turbine model.

B-7/(B-8 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


GEK 105054 Volume I Addendum C

ADDENDUM INDUSTRIAL AERODERIVATIVE GAS TURBINE MODEL LM2500-PK-MD

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


Paragraph

GEK 105054 Volume I Addendum C Title

Page

1.

INTRODUCTION .................................................................................... 4

2.

REFERENCE DATA ............................................................................... 4

2.1

Equipment................................................................................................ 4

2.2

Performance Rating................................................................................. 4

3.

SERVICE REQUIREMENTS ................................................................. 5

3.1

Natural Gas.............................................................................................. 5

3.2

Liquid Fuel............................................................................................... 5

4.

OPTIONAL HARDWARE KITS ............................................................. 5

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

GEK 105054 Volume I Addendum C 1.

INTRODUCTION

The information contained herein describes the LM2500-PK-MD model gas turbine basic configuration and control system differences. In addition, the coverage of reference data, servicing requirements, and optional hardware kits are included. 2. 2.1

REFERENCE DATA Equipment

The LM2500-PK-MD model is a marinized, dual-fueled (natural gas and liquid fuel) gas turbine. The on-engine mounted dual fuel system consists of a natural gas manifold, two liquid fuel manifolds, 30 dual fuel nozzles, and a liquid fuel off-engine mounted flow divider system. The LM2500-PK-MD gas turbine is designed to operate on 100 percent natural gas, 100 percent liquid fuel, or a combination of the two. 2.2 a.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Natural Gas: See Appendix A1. Refer to the Packager’s documentation for performance data under installed site conditions and control limits. Liquid Fuel: See Appendix A4. Refer to the Packager’s documentation for performance data under installed site conditions and control limits. NOTE The LM2500-PK-MD gas turbine can be started on either natural gas or liquid fuel but not a combination of the two. b.

The minimum fuel flow for each fuel, when operating on dual fuel, should be selected so that if one fuel is cut off the gas generator speed will not decrease below 5,000 rpm before the governor action restores the engine to normal operation

c.

Refer to Packager’s Manual for LM2500 gas turbine transient fuel flow limits.

d.

Above the idle speed range, low acceleration fuel rates will not harm the gas turbine and will only result in slower acceleration times.

e.

For normal accelerations from idle to power settings, the change should be made more slowly to enhance the time between hot section repairs and the life of the gas turbine; a time of 2 - 3 minutes is reasonable.

f.

The fuel rates in the control will give starting times to 5,000 rpm idle of 60 - 90 seconds and accelerations from idle to maximum power of 15 seconds.

Performance Rating The nominal average-rated performance of the LM2500-PK-MD gas turbine in the new and clean condition is as follows:

Shaft Horsepower: 39,000 bhp (29,082 kW) Heat Rate, Gas: 6,495 BTU/HP-Hr (9,188 kJ/kW-Hr) Heat Rate, Liquid: 6,920 BTU/HP-Hr Inlet Air Temperature: 59°F (15°C) Altitude: Sea Level Inlet Losses: 0 in. H²0 Exhaust Losses: 0 in. H²0 Relative Humidity: 60% Compressor Bleed Extraction: 0 Accessory Power Extraction: 0 Power Turbine Speed: 3,600 rpm Emission Abatement: Unabated C-4



GEK 105054 Volume I Addendum C

g.

Normal decelerations from maximum power to idle should be made in approximately 2 - 3 minutes. This will enhance the time between hot section repairs and the life of the gas turbine.

h.

The actual performance of the LM2500PK-MD gas turbine will be a function of the ratio of natural gas fuel and liquid fuel used. The time between repairs of the hot section will also change as a function of the ratio of the natural gas and liquid fuels used with the longest times being associated with 100 percent natural gas.

3.2 Liquid Fuel

SERVICE REQUIREMENTS

a.

Reference Appendix A for fuel quality.

b.

The fuel temperature supplied to the gas turbine shall be a minimum of 20° F (11°C) above the wax point of the fuel and a maximum of 150°F (65.5°C). The fuel shall be filtered to 20 microns absolute. The maximum total fuel flow required is 15,500 lb/ hr (7,030 kg/hr) with a lower heating value of 18,400 BTU/lb.

4.


3. 3.1 a.

b.

Natural Gas The required supply pressure to the natural gas fuel manifold interface on the gas generator/gas turbine is a function of both the maximum power requirements and the gas fuel properties. Refer to packager's manuals for specific requirements of gas supply pressure and gas manifold pressure for the application. For a standard pipeline quality natural gas, the maximum gas manifold pressure at maximum power will be approximately 400 psig (2757.9 kPa). The temperature of the gas supply at the fuel manifold connection on the gas turbine must be in the range of 20°F (11°C) above the saturated vapor temperature of the gas at the supply pressure as a minimum, and 350°F (177°C) as a maximum. Based on consideration of off-engine control system components however, it is recommended that the maximum gas supply temperature be limited to 150°F (65.5°C).

If the supply temperature of the gas is not repeatable on a day-to-day basis, it will be necessary to change the control system starting fuel adjustment or to adjust the supply pressure to the gas turbine to maintain a constant BTU/ft³ supply. Once started the gas turbine will accept variations in supply temperature of ± 20°F (± 11°C). The maximum fuel flow required, assuming a lower heating value of 19,000 BTU/lb is 14,500 lb/hr (6,577 kg/hr) for the LM2500-PK-MD model gas turbine.

Refer to Volume II, WP 101 00, for a detailed list of optional kits for the LM2500-PK-MD gas turbine model.

C-5/(C-6 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


GEK 105054 Volume I Addendum D

ADDENDUM INDUSTRIAL GAS TURBINE MODEL LM2500-PK-MDW

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


Paragraph

GEK 105054 Volume I Addendum D Title

Page

1.

INTRODUCTION ................................................................................... 4

2.

REFERENCE DATA .............................................................................. 4

2.1

Equipment............................................................................................... 4

2.2

Performance Rating ................................................................................ 4

2.3

Water Purity ........................................................................................... 5

3.

OPTIONAL HARDWARE KITS ............................................................ 5

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

GEK 105054 Volume I Addendum D 1.

INTRODUCTION

The information contained herein describes the LM2500-PK-MDW model gas turbine basic configuration and control system differences. In addition, the coverage of reference data, servicing requirements, and optional hardware kits are included. 2. 2.1

REFERENCE DATA Equipment

The LM2500-PK-MDW model is a marinized, dual-fueled (natural gas and liquid fuel) gas turbine. The on-engine mounted dual fuel system consists of a natural gas manifold, two liquid fuel manifolds, 30 dual fuel nozzles, and a liquid fuel off-engine mounted flow divider system. The LM2500-PK-MDW gas turbine is designed to operate on 100 percent natural gas, 100 percent liquid fuel, or a combination of the two. The LM2500-PK-MDW is equipped with a water injection system for suppression of oxides of nitrogen (NOx) in the gas turbine exhaust gases. 2.2 a.

Performance Rating The nominal average rated performance of the LM2500-PK-MDW gas turbine in the new and clean condition is as follow:

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Inlet Air Temperature: 59°F (15°C) Altitude: Sea Level Inlet Losses: 0 in.H²0 Exhaust Losses: 0 in.H²0 Relative Humidity: 60% Compressor Bleed Extraction: 0 Accessory Power Extraction: 0 Power Turbine Speed: 3,600 rpm NOx Emissions (ppm at 15% O2) - Liquid and Gas (with Nox Suppression): 42 ppm. Natural Gas: See Appendix A1. Refer to the Packager’s documentation for performance data under installed site conditions and control limits. Liquid Fuel: See Appendix A4. Refer to the Packager’s documentation for performance data under installed site conditions and control limits. NOTE

Shaft Horsepower: 40,737 bhp (30,378 kW)

The LM2500-PK-MD gas turbine can be started on either natural gas or liquid fuel but not a combination of the two.

Heat Rate, Gas with NOx Suppression: 6,691 BTU/HP-Hr (9,465 kJ/kW-Hr)

b.

The minimum fuel flow for each fuel, when operating on dual fuel, should be selected so that if one fuel is cut off the gas turbine speed will not decrease below 5,000 rpm before the governor action restores the engine to normal operation.

c.

The maximum fuel acceleration schedule for the gas turbine is provided in the Packager’s Manual

Heat Rate, Liquid with NOx Suppression: 6,847 BTU/HP-Hr (9,687 kJ/kW-Hr)

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


d.

Acceleration fuel rates greater than those shown will result in over-temperature and possible stall of the gas turbine. Acceleration fuel rates lower than those shown can result in hung starts in the below idle speed range.

e.

Above the idle speed point, low acceleration fuel rates will not harm the gas turbine and will only result in slower acceleration times.

f.

g.

For normal accelerations from idle to power settings, the change should be made more slowly to enhance the time between hot section repairs and the life of the gas turbine; a time of 2 - 3 minutes is reasonable.

GEK 105054 Volume I Addendum D h.

The actual performance of the LM2500PK-MDW gas turbine will be a function of the ratio of natural gas fuel and liquid fuel used. The time between repairs of the hot section will also change as a function of the ratio of the natural gas and liquid fuels used with the longest times being associated with 100 percent natural gas.

2.3 Water Purity Refer to Volume 1, Appendix A5, for water purity specifications. 3.


Refer to Volume II, WP 101 00, for a detailed list of optional kits for the LM2500-PK-MDW gas turbine model.

The fuel rates in the control will give starting times to 5,000 rpm idle of 60 - 90 seconds and accelerations from idle to maximum power of 15 seconds.

D-5/(D-6 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 VOLUME II



INDUSTRIAL AERODERIVATIVE GAS TURBINES


GEK 105054 Highlights of Revision 1, Dated 15 April 2010 WP - SWP 001 00

LOCATION Table 1A

DESCRIPTION OF CHANGE Updated PN in WP 200 00 in Part Number column Updated PN in WP 202 00 in Part Number column Updated PN in WP 215 00 in Part Number column Updated PN in WP 219 00 in Part Number column Added New SWP 502-01

120 00

200 00

Paragraph 5

Updated references figures

Paragraph 7

Incorporated ICN GEK 105054-23

Paragraph 6

Updated step e., substeps e.(1), e.(2), and e.(2)(a) thru e.(2)(d) Updated PN in substep f.(6)

Figure 3

Updated

Paragraph 7

Updated PN in step a., substeps c.(5), and c.(6)

Paragraph 3

Changed PN to item in Support Equipment list

Paragraph 6

Changed PN in step e.

Paragraph 7

Changed PN in steps e. and f.

Paragraph 3


Paragraph 7

Changed PN in substep e.(3)

Paragraph 8

Changed PN in substep f.(8)

Paragraph 9

Changed PN in step e.

Paragraph 3


Paragraph 7

Changed PN in step c.

406 00

Table 7

Updated item 8.d. in On-Site Maximum Serviceable Limits column

418 00

Table 1

Updated items 5A.a. and b. in On-Site Maximum Serviceable Limits column

422 00

Table 1

Updated item 1.a. in On-Site Maximum Serviceable Limits and On-Site Maximum Repairable Limits columns

502 00

Figure 4

Updated

502 01

Entire

Created SWP

202 00

215 00

219 00

GEK 105054 VOLUME II



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

COPYRIGHT 2010 General Electric Company, USA


15 APRIL 2009 Change 1 - 15 April 2010

GEK 105054 Volume II


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

LIST OF EFFECTIVE PAGES Dates of issue for original and change pages are listed below: Original ............. Change ..............

0 ....... 1 .......

15 April 2009 15 April 2010

Interim Change Notice (ICN) GEK 105054-23, dated 8 February 2010, is incorporated in this change. Total number of pages in this volume is 1376, consisting of the following: Page No.

Change No.

Title

1

A to B/(C Blank)

1

i to iv

1

WP/SWP No. WP 001 00 WP 002 00 WP 100 00 WP 101 00 SWP 101 01 SWP 101 02 SWP 101 03 SWP 101 04 SWP 101 05 SWP 101 06 SWP 101 07 SWP 101 08 SWP 101 09 SWP 101 10 SWP 101 11 SWP 101 12

Change No. 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

A

WP/SWP No. SWP 101 13 WP 102 00 SWP 102 01 WP 103 00 WP 104 00 WP 105 00 WP 106 00 WP 107 00 SWP 107 01 WP 108 00 WP 109 00 WP 110 00 WP 111 00 WP 112 00 WP 113 00 SWP 113 01

Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0




WP/SWP No. WP 114 00 WP 115 00 WP 116 00 SWP 116 01

List of Effective Pages - (Cont.) Change No. WP/SWP No. 0 WP 302 00 0 WP 303 00 0 WP 400 00 0 WP 401 00

WP 117 00 SWP 117 01

0 0

WP 402 00 WP 403 00

WP 118 00 WP 119 00 WP 120 00 WP 121 00 WP 122 00 WP 123 00 WP 124 00 WP 200 00 WP 201 00 SWP 201 01 SWP 201 02 WP 202 00 WP 203 00 WP 204 00 WP 205 00 WP 206 00 WP 207 00 WP 208 00 WP 209 00 WP 210 00 WP 211 00 WP 212 00 WP 213 00 WP 214 00 WP 215 00 WP 216 00 SWP 216 01 SWP 216 02 WP 217 00 SWP 217 01 WP 218 00 WP 219 00 WP 220 00 WP 221 00 WP 300 00 WP 301 00

0 0 1 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0

WP 404 00 WP 405 00 WP 406 00 WP 407 00 WP 408 00 WP 409 00 WP 410 00 WP 411 00 WP 412 00 WP 413 00 SWP 413 01 WP 414 00 WP 415 00 WP 416 00 WP 417 00 WP 418 00 WP 419 00 WP 420 00 WP 421 00 WP 422 00 WP 423 00 WP 424 00 WP 425 00 WP 426 00 WP 427 00 WP 428 00 WP 429 00 WP 430 00 WP 431 00 WP 500 00 WP 501 00 WP 502 00 SWP 502 01 WP 503 00 WP 504 00

Change No. 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0

Change 1

B/(C Blank)




Table of Contents WP/SWP Number

Title

LEVEL 1 MAINTENANCE WP 001 00 WP 002 00 WP 100 00 WP 101 00 SWP 101 01 SWP 101 02 SWP 101 03 SWP 101 04 SWP 101 05 SWP 101 06 SWP 101 07 SWP 101 08 SWP 101 09 SWP 101 10 SWP 101 11 SWP 101 12 SWP 101 13 WP 102 00 SWP 102 01 WP 103 00 WP 104 00 WP 105 00 WP 106 00 WP 107 00 SWP 107 01 WP 108 00 WP 109 00 WP 110 00 WP 111 00 WP 112 00 WP 113 00 SWP 113 01 WP 114 00 WP 115 00 WP 116 00 SWP 116 01

Numerical List of Support Equipment and List of Consumable Materials General Maintenance Practices Variable Stator Vane Actuator Replacement Fuel System Replacement Liquid Fuel Nozzle Replacement Liquid Fuel With Steam Injection Fuel Nozzle Replacement Liquid Fuel With Water Injection Fuel Nozzle Replacement Natural Gas Fuel Nozzle Replacement Natural Gas With Steam Injection Fuel Nozzle Replacement Natural Gas With Water Injection Fuel Nozzle Replacement Dual Fuel Nozzle Replacement Dual Fuel With Steam Injection Fuel Nozzle Replacement Liquid Fuel Manifold Replacement Natural Gas Fuel Manifold Replacement Dual Liquid Manifold Replacement Steam Manifold Replacement Water Manifold Replacement Five Element Lube and Scavenge Pump Replacement Six Element Lube and Scavenge Pump Replacement Igniter Plug and Ignition Lead Replacement Ignition Exciter Replacement Gas Generator Speed Sensor Replacement Power Turbine Speed Transducer Electrical Cable Replacement Power Turbine Speed Transducer Replacement Power Turbine Dual Output Speed Transducer Replacement Thermocouple Probe (T5.4) and Harness Replacement High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Replacement Lube System Temperature Sensor Replacement Accelerometer Replacement Power Turbine Inlet Pressure (P5.4) Probe Replacement Gas Generator Outside Piping and Wiring Removal and Installation Gas Turbine Outside Piping and Wiring Removal and Installation Variable Stator Vane Torque Shaft Replacement Fuel Pump Replacement Air/Oil Separator Replacement Air/Oil Separator Cover Replacement


i


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table of Contents - (Cont.)

WP/SWP Number WP 117 00 SWP 117 01 WP 118 00 WP 119 00 WP 120 00 WP 121 00 WP 122 00 WP 123 00 WP 124 00

Title Pneumatic Starter (Shrouded/Nonshrouded) Replacement Hydraulic Starter Replacement Ultraviolet Flame Sensing System Components Replacement Accessory Gearbox Carbon Seals Replacement Hydraulic Pump Replacement Variable Stator Vane Servovalve Replacement Hydraulic Filter Housing and Element Replacement High Pressure Compressor Discharge Temperature (T3) Sensor Replacement Magnetic Detector Plug Replacement

LEVEL 2 HORIZONTAL MAINTENANCE WP 200 00 WP 201 00 SWP 201 01 SWP 201 02 WP 202 00 WP 203 00 WP 204 00 WP 205 00 WP 206 00 WP 207 00 WP 208 00 WP 209 00 WP 210 00 WP 211 00 WP 212 00 WP 213 00 WP 214 00 WP 215 00 WP 216 00 SWP 216 01 SWP 216 02 WP 217 00 SWP 217 01 WP 218 00 WP 219 00 WP 220 00 WP 221 00

ii

Turbine Mid Frame Replacement High Pressure Turbine Rotor Replacement High Pressure Turbine Stage 2 Nozzle Assembly Replacement High Pressure Turbine Stage 1 Nozzle Assembly Replacement High Pressure Turbine Rotor Blade Replacement Single Annular Combustor Replacement Gas Generator Inlet Duct Replacement Centerbody Replacement Accessory Gearbox Replacement Radial Drive Shaft Replacement Inlet Gearbox Replacement Variable Stator Vane Mechanism Replacement Compressor Front Frame Replacement High Pressure Compressor Stator Casings Replacement High Pressure Compressor Variable Stator Vane Replacement High Pressure Compressor Variable Stator Vane Shroud Replacement High Pressure Compressor Fixed Stator Vane Replacement High Pressure Compressor Rotor Blades Replacement Gas Generator and Power Turbine Separation and Joining Two Stage Power Turbine And Gas Generator Joining Kit Gas Generator Joining Kit Gas Generator Miscellaneous Sump Components Replacement Gas Turbine Miscellaneous Sump Components Replacement Six Stage Power Turbine Stator Casings Removal and Installation Six Stage Power Turbine Stage 1 Rotor Blade Replacement Power Turbine Forward Adapter Replacement LPT Stage 1 Nozzle Assembly Replacement




Table of Contents - (Cont.) WP/SWP Number

Title

GAS GENERATOR, GAS TURBINE, AND SIX STAGE POWER TURBINE CHANGEOUT WP 300 00 WP 301 00 WP 302 00 WP 303 00

Gas Turbine Assembly Replacement Gas Generator Assembly Replacement Power Turbine Assembly Replacement Maintenance Dolly Usage

GAS GENERATOR, GAS TURBINE, SIX STAGE POWER TURBINE INSPECTIONS WP 400 00 WP 401 00 WP 402 00 WP 403 00 WP 404 00 WP 405 00 WP 406 00 WP 407 00 WP 408 00 WP 409 00 WP 410 00 WP 411 00 WP 412 00 WP 413 00 SWP 413 01 WP 414 00 WP 415 00 WP 416 00 WP 417 00 WP 418 00 WP 419 00 WP 420 00 WP 421 00 WP 422 00 WP 423 00 WP 424 00 WP 425 00 WP 426 00 WP 427 00 WP 428 00 WP 429 00 WP 430 00 WP 431 00

Lube and Scavenge Pump Screen, Electronic Chip Detector, and Magnetic Detector Plug Inspection Gas Generator Inlet Inspection External Engine Cleaning External Engine Inspection Gas Turbine Exhaust System Inspection Water-Wash Borescope Inspection Lube Oil Sampling Hydraulic Pump Filter Element Inspection Ignition System Functional Check Vibration Monitoring System Functional Check Overspeed Inspection Overtemperature Inspection Gas Generator Miscellaneous Sump Components Inspection Gas Turbine Miscellaneous Sump Components Inspection Variable Stator Vane Off-Schedule Inspection Fuel System Inspection Compressor Front Frame Inspection High Pressure Recoup Metering Spacer Selection Variable Stator Vane System Inspection Thermocouple Probe (T5.4) Inspection Accessory Gearbox Inspection Six Stage Power Turbine Components Inspection Six Stage Power Turbine Stages 1 and 6 Rotor Blade Inspection High Pressure Compressor Stator Casings Inspection High Pressure Compressor Rotor Inspection Single Annular Combustor Inspection High Pressure Turbine Rotor Inspection High Pressure Turbine Stage 1 Nozzle Inspection High Pressure Turbine Stage 2 Nozzle Inspection Turbine Mid Frame Inspection High Pressure Compressor Variable Stator Vane Shrouds Inspection Power Turbine Thrust Balance Cavity Pressure System Orifice Plate Selection


iii


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table of Contents - (Cont.)

WP/SWP Number

Title

PRESERVATION, HANDLING, AND STORAGE WP 500 00 WP 501 00 WP 502 00 SWP 502 01 WP 503 00 WP 504 00

iv

Gas Generator/Gas Turbine Preservation, Depreservation, and Storage Maintenance Power Turbine Preservation, Depreservation, and Storage Maintenance Gas Generator/Gas Turbine Shipping Air Ride Kit Installation Power Turbine Shipping Shipping Container Inspection and Reconditioning


GEK 105054 Volume II WP 001 00


WORK PACKAGE

TECHNICAL PROCEDURES NUMERICAL LIST OF SUPPORT EQUIPMENT AND LIST OF CONSUMABLE MATERIALS (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE WP PAGES Total Number of Pages in this WP is 24 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 24 ................. 1 Alphabetical Index Subject

Page

Consumable Materials. ....................................................................................................... 23 Support Equipment. ............................................................................................................ 3


1

GEK 105054 Volume II WP 001 00 1.


Introduction. This work package provides lists of recommended mechanic’s hand tools, consumable materials, and special support equipment required to maintain the LM2500+ SAC engine.

2.

Reference Material. AERO ENERGY Products And Services Directory. Tooling/Support Equipment www.GSETools.com or 1-877-GSETool Title Marine and Industrial Engines Ground Support Equipment Catalogue

3.

Support Equipment. See paragraph 6.table 1 and table 1A.

4.

Consumable Material. See table 2.

5.

Expendable Material. None required.

2



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6.

Support Equipment. a.

For applicable special support equipment, refer to AERO ENERGY Products And Services Directory. Refer to table 1A.

b.

For recommended mechanic’s hand tools, consult table 1. Hand tools are obtained by local purchase. Vendor part number and codes are provided for reference only. Table 1. Recommended Mechanic’s Hand Tools

Tool Type

Size

Qty

Part Number

Vendor Code

Vendor Code: A = Snap-on B = Utica/Triangle C = Starrett D = Rigid E = Cole Manufacturing F = Alphatron G = Apex Company Adapter

1/4F by 3/8M 3/8F by 1/4M 3/8F by 1/2M 1/2F by 3/8M 1/2F by 3/4M 3/8F by 1/2M

1 1 1 1 1 1

GTA-3 GTM-1 GAF-2 GAX-1 GLA-12A GLA-2

A A A A A A

Adapter, Torque - 12 pt (Thin Wall) (3/8 Drive)

1/4 5/16 3/8

1 1 1

GFRDH-081 GFRDH-101 GFRDH-121

A A A

Adapter, Torque (Spline) (3/8 Drive - 2 inch Offset)

5/16 3/8 7/16

1 1 1

GFRES-10 GFRES-12 GFRES-14

A A A

Bar, Breaking

1/4 Drive 3/8 Drive 1/2 Drive

1 1 1

GTM-l0F GF-10M GSN-18A

A A A

Bar, Pry

16 Inch

1

1650

A

Colorbrite Silver

1

2101

A

Crimping Tool, Safety Cable

1

CTK-8V32A

A


3


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Recommended Mechanic’s Hand Tools - (Cont.) Vendor Code

Tool Type

Size

Qty

Crowfoot - 12 Pt (1/4 Drive)

1/4 5/16 3/8

1 1 1

TMRX-8 TMRX-10 AN-8508-6A

A A A

Crowfoot, Open End (3/8 Drive) Crowfoot - 12 Pt (3/8 Drive)

3/8

1

GFC-012

A

5/8 11/16 3/4

1 1 1

GAN-8508-10 GAN-8508-11 GAN-8508-12

A A A

Crowfoot, Flare Nut - 6 Pt (3/8 Drive)

9/16 5/8 11/16 3/4

1 1 1 1

FRH-180S FRH-200S FRH-220S FRH-240S

A A A A

Crowfoot, Open end (1/2 Drive)

1-1/8 1-1/4 1-1/2 1-3/4 2 2 Inch 4 Inch Wobble 6 Inch 6 Inch Wobble 14 Inch 3 Inch Wobble 6 Inch 12 Inch 8 Inch Wobble

1 1 1 1 1 1 1 1 1 1 1 1 1 1

GSC-036 GSC-040 GSC-048 GSC-056 GSC-064 GTMX-2 GTMXW-4 GTMX-60 GTMXW-60 GTMX-140 GFXW-3 GFX-6 GFX-11A GFW-8A

A A A A A A A A A A A A A A

5 Inch 10 Inch

1 1

GS-5 GS-10

A A

Extension (1/4 Drive)



4

Part Number



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Recommended Mechanic’s Hand Tools - (Cont.) Tool Type

Size

Qty

Part Number

Vendor Code

Extension, Swivel Socket (3/8 Drive)

3/8 Inch

l

RC312-3/8

G

(3/8 Drive)

7/16 Inch

1

RC312-7/164

G

2 Cell

1

ECF-35

A

Pocket Rule

6 Inch

1

PMF-131

A

Feeler Gage

26 blade

1

FB-335

A

Compothene

24 Oz

1

458-24

A

Plastic Tip

16 Oz

1

BE-116

A

Soft-Faced

13 Inch

1

BH-232-2

A

Ball Peen

16 Oz

1

BPN-16B

A

Ball Peen

32 Oz

1

BPN-32A

A

3/8 Drive

1

GF-4LA

A

1/2 Drive

1

KB-4

A

1/4 Drive, 5 Inch

1

TM-75A

A

3/8 Drive, 7 Inch

1

F-720B

A

1/2 Drive, 10 Inch

1

GS-710A

A

17-3/4 Inch

1

GA-265A

A

Inspection

1-1/4 Inch Dia

1

CF-143A

A

Inspection

2-1/4 Inch Dia

1

GA-295

A

1

CF-157A

A

Flashlight Gage -

Hammer -

Handle, Speed

Handle, Ratchet

Mechanical Fingers Mirror -

Oval Pocket


5


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Recommended Mechanic’s Hand Tools - (Cont.)

Tool Type

Size

Qty

Part Number

Vendor Code

Pliers Bent Needle Nose

1 Inch

1

497ACP

B

Safety Wire Twister

10-1/2 Inch

1

GA-311C

A

Diagonal Cutting

5-1/16 Inch

1

87ACP

A

Diagonal Cutting

1

388ACP

A

Needle Nose

1

196ACP

A

Needle Nose

1

95ACP

A

Flat Nose

1

61CP

B

1

46C

B

1

91CP

A

Standard

6 Inch

Adjustable Joint Punch Nylon

3/4 Dia by 12 Inch

1

PPC-1002

A

Bronze

3/4 Dia by 12 Inch

1

PPC-108A

A

Pin Set

1/4 Dia

1

PPC-110A

A

Pin Set

5/16 Dia

1

PPC-208A

A

Starter

1/4 Dia

1

PPC-905A

A

Common

4 by 1/4 Inch Blade Tip

1

GSSD-44

A

Common

6 Inch

2

SDD-6

A

Common


2

SDD-46

A

Common

8 Inch

2

SDD-8

A

Common


2

SDD-48

A

Phillips No. 1

Pocket Size

2

SDDP-204

A

Phillips No. 1

6 Inch

2

SDDP-61

A

Phillips No. 2

12 Inch

2

SDDP-62

A

Torx Tip Bit

No. 30

2

STDTX-430

C

Torx Tip Bit

No. 40

2

STDTX-430

C

1

PTS-5

A

Screwdriver -

Scriber

6



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Recommended Mechanic’s Hand Tools - (Cont.)

Qty

Part Number

5/32 Hex bit

1

GTMD-5

A

3/16

1

GTMD-6

A

3/16 Deep Well

1

GSTMD-6

A

7/32

1

GTMD-7

A

7/32 Deep Well

1

GSTMD-7

A

1/4

1

GTMD-8

A

1/4 Deep Well

1

GSTMD-8

A

5/16

1

GTMD-10

A

5/16 Deep Well

1

GSTMD-10

A

3/8

1

GTMD-12

A

3/8 Deep Well

1

GSTMD-12

A

7/16

1

GTMD-14

A

7/16 Deep Well

1

GSTMD-14

A

1/2

1

GTMD-16

A

1/2 Deep Well

1

GSTMD-16

A

9/16

1

GTMD-18

A

9/16 Deep Well

1

GSTMD-18

A

1/4

1

GTES-8

A

5/16

1

GTES-10

A

5/16 Deep Well

1

GTEL-10

A

5/16 Universal

1

GTESU-10

A

1/4

1

GTMU-81

A

5/16

1

GTMU-101

A

3/8

1

GTMU-121

A

7/16

1

GTMU-141

A

1/2

1

GTMU-161

A

Tool Type

Size

Socket - 12 Pt

Socket - Spline (1/4 Drive)

Socket, Universal - 12 Pt (1/4 Drive)

Vendor Code


7


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Recommended Mechanic’s Hand Tools - (Cont.) Part Number

Vendor Code

Tool Type

Size

Qty

Socket, Spline

3/8

1

GFES-120

A

3/8 Deep Well

1

GFEL-120

A

3/8 Universal

1

FESU-120

A

7/16

1

GFES-140

A

7/16 Deep Well

1

GFEL-140

A

7/16 Universal

1

FESU-140

A

9/16 Deep Well

1

GFEL-180

A

9/16 Universal

1

FESU-180

A

5/8 Deep Well

1

GFEL-200

A

5/8 Universal

1

FESU-200

A

No. 40

1

3/8

1

IPF-12

A

(3/8 Drive)

7/16

1

IPF-14

A

Socket - 12 Pt

5/16

1

GF-100

A

5/16 Deep Well

1

GSF-100

A

3/8

1

GF-121

A

3/8 Deep Well

1

GSF-121

A

3/8 Square Female

1

PP-412

A

7/16

1

GF-141

A

7/16 Deep Well

1

GSF-141

A

1/2

1

GF-161

A

1/2 Deep Well

1

GSF-161

A

9/16

1

GF-181

A

9/16 Deep Well

1

GSF-181

A

5/8

1

GF-201

A

5/8 Deep Well

1

GSF-201

A

11/16

1

GF-221

A

3/4

1

GF-241

A

(3/8 Drive)

Socket - Torx

A

(3/8 Drive) Socket - Swivel - 6 Pt

(3/8 Drive)

8



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Recommended Mechanic’s Hand Tools - (Cont.) Part Number

Vendor Code

Tool Type

Size

Qty

Socket - Universal - 12 Pt

5/16

1

GFU-10A

A

3/8

1

GFU-12A

A

7/16

1

GFU-14A

A

1/2

1

GFU-16A

A

Socket, Spline

9/16

1

GSES-181

A

(1/2 Drive)

5/8

1

GSES-201

A

l

KRW-48A

A

(3/8 Drive)

Toolbox Wrench, Allen - Set

3/64 - 3/8

2

AW-1013AK

A

Wrench, Box

3/16 by 7/32

1

GSX-67

A

1/4 by 5/16

1

GSXO-810

A

3/8 by 7/16

1

GSXO-1214

A

1/2 by 9/16

1

GSXO-1618

A

5/8 by 3/4

1

GSXO-2024

A

1/4 by 5/16

1

GV0810

A

5/16 by 3/8

1

GVO1012

A

3/8 by 7/16

1

GVO1214

A

7/16 by 1/2

1

GVO1416

A

1/2 by 9/16

1

GVO1618

A

9/16 by 5/8

1

GVO1820

A

5/8 by 11/16

1

GVO2022

A

5/8 by 3/4

1

GVO2024

A

3/8 by 7/16

2

RXF1214B

A

1/2 by 9/16

2

RXFS1618B

A

5/8 by 11/16

2

RXFS2022A

A

3/4 by 13/16

2

RXFS2426A

A

3/16 by 7/32

1

GXDH-67

A

1/4 by 5/16

1

GXDH-810B

A

3/8 by 7/16

1

GXDH-1214A

A

1/2 by 9/16

1

GXDH-1618A

A

(offset)

Wrench, Open End

Wrench, Flare Nut - 6 Pt

Wrench, Box - 12 Pt


9


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Recommended Mechanic’s Hand Tools - (Cont.) Vendor Code

Tool Type

Size

Wrench, Box - 12 Pt

1/4 by 5/16

1

GR-810A

A

3/8 by 7/16

1

GR-1214A

A

7/32 by 1/4

1

66069

A

5/16 by 3/8

1

66040

A

7/16 by 1/2

1

66042

A

1/4

2

GOEX-80

A

5/16

2

GOEX-100

A

3/8

2

GOEX-120

A

7/16

2

GOEX-140

A

1/2

2

GOEX-160

A

9/16

2

GOEX-180

A

5/8

2

GOEX-200

A

11/16

1

GOEX-220

A

3/4

2

GOEX-240

A

2

E-110

1/4 by 5/16

2

GXDES-810

A

3/8 by 7/16

2

GXDES-1214

A

1/2 by 9/16

1

GXDES-1618

A

9/16 by 5/8

1

GXDES-1820

A

13/16 by 15/16

1

GXDES-2630

A

Wrench, Spanner Hook

1/4 Pin

1

474B

A

Wrench, Torque

1/4 Drive, 30-200 lb in.

1

AJR-117E

A

1/2 Drive, 30-250 lb ft

1

QJR-3250A

A

(ratchet) Wrench, Box - 12 Pt (thin wall)

Wrench, Combination - 12 Pt

Wrench, Rigid Offset Wrench, Spline

10

Qty

Part Number




Table 1A. Special Tooling

Work Package


Part Number

Nomenclature

WP 100 00

-

1C3569G2/G3

Assembly, Hydraulic Actuator Unit

1C9403G01

Fixture, Check - Actuator, Variable Stator

SWP 101 01

2C6081G06

Adapter Set - Fuel Manifold

SWP 101 09

Local Purchase

Nylon Sling

SWP 101 10

Local Purchase

Nylon Sling

SWP 101 11

Local Purchase

Nylon Sling

SWP 101 12

Local Purchase

Nylon Sling

1C8204

Wrench Set - Steam Tube

Local Purchase

Nylon Sling

WP 101 00

SWP 101 13 WP 103 00

-

1C6096G01

Gage, Depth

WP 105 00

-

Local Purchase

Gage, Feeler

WP 107 00

-

1C6345G01

Gage, Clearance - Overspeed Transducer

SWP 107 01

1C60804G04

Set, Jackscrew

Local Purchase

Nylon Sling

WP 114 00

-


11


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1A. Special Tooling - (Cont.)

Work Package


WP 116 00

-

SWP 116 01 WP 116 00

SWP 116 01

WP 119 00

-

WP 200 00

12

-

Part Number

Nomenclature

1C6804G04

Tool Set, Jackscrew - Disassembled Flanges

1C8033G01

Adapter, Splined - TGB, Borescope Inspection

1C8067G02

Motor, Drive - Gas Generator Inspection

9441M27G01

Puller, Bearing Liner - Transfer Gearbox

1C6842G01

Tool Set, Transfer Gearbox

9407M45

Air/Oil Separator Cover Puller

Local Purchase

Heat Gun

Local Purchase

Soft-Faced Mallet

1C8182G01

Fixture Set - Removal, Mating Seal

Locally Mfg.

Pin, Guide

1C6804G04

Jackscrews, Flange Disassemble Tool Set

1C8351G01

Lift Fixture, Turbine Mid Frame




Work Package


WP 201 00

-

Part Number

Nomenclature

1C5937G01

Gage, Vertical Concentricity Bearing 5 Inner Ring

1C6804G04


1C6897G02

Wrench, Spanner - No. 5 Bearing Retaining Nut

1C6950G05

Wrench, Spanner - High Pressure Turbine Rotor Coupling Nut

1C8059G01

Stand, Vertical - High Pressure Turbine Rotor Engine Maintenance Unit

1C8069G04

Fixture, Lift - High Pressure Turbine Rotor, Horizontal

2C6058G04

Wrench, Spanner - Oil Tube High Pressure Turbine Rotor

2C6063G01

Puller, Retaining Ring - Bearing 5

2C6141G02

Lifteye - High Pressure Turbine Rotor, Aft

2C6341G02

Wrench, Spline, Direct Drive

2C6563G01

Tool, Install/Remove - High Pressure Turbine Damper Sleeve


13



Work Package


Part Number

Nomenclature

2C6110G01

Pin, Guide Stage 2 High Pressure Turbine Nozzle Assembly

Sweeny Model 8200 or equivalent

Multiplier, Torque

SWP 201 01

1C5964G01

Sling, Lift - High Pressure Turbine, Stage 2 Nozzle Assembly

SWP 201 02

1C6804G04

Tool Set, Jackscrew - Disassembled Flanges

1C8217G01

Fixture, Lift - HPT Nozzle, Stage 1

Local Purchase

Gun, Heat

BLADEOPT

Program, Computer Airfoil Balancing

Local Purchase

Stock, Feeler

2C6264G03

Truck, HPT Rotor Transportation and Storage

9446M61G01

Program, Balance - Blade Installation/Replacement

2C6066G03

Fixture, Lift Combustion Liner, Horizontal

Local Purchase

Rod, Steel 0.400-0.407 in. (10.17-10.33 mm) Dia

WP 201 00

WP 202 00

-

WP 203 00

14

-

WP 204 00

-

Local Purchase

Nylon Sling

WP 206 00

-

1C5654G03 or 2C6301G02

Jack, Lowering - Engine Components

1C6119G01

Guide, Expandable Bushing

1C6872G01

Jack, Fixture, Installation & Removal - Access Gearbox, Horizontal




Work Package


WP 207 00

Part Number

Nomenclature

-

1C6361G01

Tool Set, Radial Drive Shaft

WP 207 00

-

1C6804G04

Tool Set, Jackscrew - Disassemble Flanges

WP 208 00

-

1C8099P01

Protector, Strut Cavity - Compressor Front Frame

Local Purchase

Mallet, Soft Plastic

1C3569G2/G3


1C8324G01

Holder Set, Variable Stator Vanes

1C8332G01

Fixture, Lift - Gas Generator Turnover Front Frame

2C6119G02

Shim Set, Blade Tips - Compressor Rotor

1C3569G2/G3


1C8039G02

Fixture, Raise and Support Upper Compressor Case

1C8343G01

Fixture Set, Top Halving - HP Compressor Stator Case

1C8350G01

Lift Fixture - HPC Stator Case

1C8324G01


WP 209 00

WP 210 00

WP 211 00

WP 212 00

-

-

-

-


15



Work Package


WP 214 00

-

Part Number

Nomenclature

2C6019G01

Driver Set - Compressor Stator Vane

2C7373G01

Seating Tool, Vane Liner, Compressor Stator Case - Front & Rear

2C7373G03


2C7373G05


2C7373G06


Local Purchase

Rod, Steel 0.400-0.405 in. (10.17-10.29 mm) Dia

BLADEOPT

Program, Computer Airfoil Balancing

1C8312G01

Tool Set, Remove High Pressure Compressor Rotor Stage 1 and 2 Retaining Ring

2C6019G01

Driver Set - Compressor Stator Vane

9446M61G01


1C8321G01

Mount Set, Ground Handling Power Turbine

1C6955G03

Fixture, Lift-Power Turbine Assembly

SWP 216 01

Local Purchase

Heat Gun

SWP 216 02

Local Purchase

Heat Gun

WP 215 00

-

WP 216 00

16

-




Work Package


WP 217 00

-

SWP 217 01

Part Number

Nomenclature

1C6804G04


1C6898G01

Pins, Guide - Brg and Seal Installation

1C6899G01

Puller, No. 5R Bearing Inner Race

1C6905G01

Clamping Set, O-Ring Installation

2C6196G01

Pusher, No. 5R Bearing Inner Race

2C6001G01

Wrench, No. 3R Bearing Race Spanner Nut

2C6002G01

Pusher, No. 3R Bearing Inner Race

2C6003G01

Puller, No. 3R Bearing Inner Race

Sweeny Model 8100

Multiplier, Torque

Local Purchase

Pump, Enerpac Hydraulic

1C5691G04

Puller, No. 6R Bearing Inner Race and Rotating Oil Seal


17



Work Package


WP 217 00

SWP 217 01

WP 218 00

18

-

Part Number

Nomenclature

1C5702G01

Pusher, No. 6R Bearing and Seal Race

1C6804

Set, Jackscrew

1C6856G01

Wrench, No. 6R bearing spanning nut

1C6898

Pins, Alignment

1C6905G01

Clamping Set, O-Ring Installation

Sweeny, Model 8100

Multiplier, Torque

Local Purchase


1C5634G01

Fixture, Lift - Lower Pressure Turbine Stator, Lower

1C5654G03


1C6868G03

Fixture, Drive - Lower Pressure Turbine Rotor

1C6871G01

Case, Dummy - Low Pressure Turbine Rotor

1C8032G03

Fixture, Hinge - Low Pressure Turbine Stator Case

1C8042G01

Fixture, Lift and Support - Low Pressure Turbine Stator Case, Upper

1C8322G01

Fixture, Lift - Lower Pressure Turbine Stator, Upper

Sweeny Model 8200 or equivalent

Multiplier, Torque




Work Package


WP 219 00

-

Part Number

Nomenclature

1C6702G01

Tool Set, LPT Rotor Retainer

9446M61G01


WP 220 00

-

1C6364G02

Torque Adapter-Forward Adapter, Coupling Nut

WP 220 00

-

1C8344G01

Puller Shaft-Forward Adapter

Sweeny Model 8100 or Model 8200

Multiplier, Torque

Local Purchase


WP 300 00

-

1C8341G01

Fixture, Lift-Gas Turbine

WP 301 00

-

1C8341G02


WP 302 00

-

1C6955G03

Fixture, Lift-Power Turbine

1C8321G01


106C7157G01

Container, Shipping


19


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1A. Special Tooling

20

Work Package


WP 303 00

-

Part Number

Nomenclature

1C6955G03

Fixture, Lift - Power Turbine Assembly

1C8302G05

Adapter Assembly, Maintenance Dolly

1C8321G01


1C8333G01

Jack Assembly, Support Compressor Rear Frame

1C8340G01

Fixture, Lift - Gas Generator

1C8341G01

Fixture, Lift - Gas Turbine

1C8342G01

Fixture, Aft Lift and Turn Power Turbine

1C9372G05

Frame Assembly, Maintenance Dolly

106C7157G01

Shipping Container - Power Turbine

9448M49G01

Bar, Tow (for use with 1C9372)

Local Purchase

Sling, Nylon (1,000 lb [453kg] minimum rating)

WP 400 00

-

Local Purchase

Multimeter

WP 406 00

-

1C3569G2/G3


1C8208G02

Spline, Adapter, Manual or Front Drive Pad

2C14764G05

Drive Motor, Electric

2C14764G06

Drive Motor, Electric

2C6388G06

Borescope, Rigid

856A1321

Borescope, Flexible




Work Package


WP 410 00 WP 413 00

WP 414 00

Part Number

Nomenclature

-

Local Purchase

Multimeter

-

Local Purchase

Comparator, Optical - Pocket Sized

SWP 413 01

Local Purchase


1C8070G06

Protractor, Electronic

2C6966G07

Gage, Sight - VSV Actuation Arms

2C8016G03

Gage, Sight - VSV Stage 5 Actuation Arms

-

WP 419 00

-

Local Purchase

Multimeter

WP 422 00

-

2C6388G06

Borescope, Rigid

856A1321

Borescope, Flexible

WP 427 00

-

2C6505

Gage, High Pressure Turbine Nozzle Open Area

WP 500 00

-

1C8208G02

Spline, Adapter, Manual or Aft Drive Pad

2C14764G01

Drive Motor, Electric (115 Vac)

2C14764G02

Drive Motor, Electric (220 Vac)

2C14764G05

Drive Motor, Electric (115 Vac/220 Vac)

Local Purchase

Stand, Portable Lubricating


21



Work Package


WP 502 00

-

SWP 502 01

WP 503 00

22

-

Part Number

Nomenclature

1C8017G01

Set, Lift Attachment

1C8340G01

Fixture, Lifting - Gas Generator

1C8341G01

Fixture, Lifting - Gas Turbine

106C7156P02

Container, Shipping - LM2500 Universal

Local Purchase

Lift, Quad Link (6,000 lb [2721 kg] minimum rating)

Local Purchase


00202050000

Kit, Air Ride

106C7156P02

Container, Shipping - LM2500 Universal

1C6955G03

Fixture, Lifting - Power Turbine

1C8321G01

Mount Set, Ground HandlingPower Turbine

1C8342G01

Fixture, Aft Lift and Turn Power Turbine

1C9372G04

Frame Assembly, Maintenance Dolly

106C7157P01

Container, Shipping - Power Turbine

Local Purchase

Lift, Quad Link (6,000 lb [2721 kg] minimum rating)

Local Purchase


Local Purchase

Gun, Heat




Consumable Materials. a.

Refer to table 2 for list of applicable consumable material. CAUTION THE FOLLOWING MATERIALS SHALL NOT BE USED FOR MARKING GAS PATH COMPONENTS:

•

ALL GRAPHITE PENCILS

•

WHITE DYKEM DXX-327

•

AERO BRAND, BLACK OPAQUE STAMPING INK Table 2. Consumable Materials

Nomenclature

Specification

Acetone

GE Spec. D50TF13

Antiseize Compound

Milk of Magnesia (Unflavored) Local Purchase

Barrier Paper

MIL-B-121, Type I, Class 2

Chromate Free Primer Paint

MIL-P-2444/1

Desiccant

MIL-P-116

Desiccant

MIL-D-3464

Dry Film Lubricant

GE Spec A50TF192

Dry Ice

Fed Spec BB-C-104

Engine Preservation Oil

MIL-L-6529, Type III

Epoxy Polymide Topcoat Paint

MIL-C-22750

Fuel System Preservation Oil

MIL-L-6081C, Grade 1010

Gasket Material

MIL-R-6855, CL-II

Grease

MIL-G-23827

Hydraulic Fluid

MIL-H-17672

Isopropyl Alcohol

TT-I-735

Lint-Free Cloths

Local Purchase

Liquid Wrench

Local Purchase

Lubricating Oil

MIL-L-23699

Lubricating Oil

MIL-L-7808

Marking Dye

Dykem DX100

Marking Pen

Action Marker

Marking Pen

Sharpie T.E.C.

Masking Tape

Local Purchase Change 1


23


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Consumable Materials - (Cont.)

Nomenclature

Specification

Mastic Sealant

Local Purchase

Molybdenum Disulfide Grease

MIL-G-21164 CAUTION

LIQUID WRENCH NO. 1 IS ACCEPTABLE IN APPLICATIONS WHERE USE OF PENETRATING OIL IS SPECIFIED. DO NOT USE WD-40. Penetrating Oil

GE Spec A50TF54, Class A

Petrolatum

Fed Spec VV-P-236

Plastic Bag

Local Purchase

Rust Preventative Concentrate

GE Spec D50TF6

Rust Preventative Concentrate

Brayco 599

Safety Cable (0.032 inch)

736L680G01

Safety Wire (0.020 inch)

R297P02

Safety Wire (0.032 inch)

R297P04

Sealant

GE Spec A50TF272

Sealing Compound

GE Spec A50TF26

Silicone Rubber Adhesive (RTV 103) Black

GE Spec A15F6A3

Silicone Rubber Adhesive (RTV 106) Red

GE Spec A15F6B6

Shop Rags

Local Purchase

Soft Bristle Brush

Local Purchase

Soap Solution

Local Purchase

Thread Lubricant

GE Spec A50TF201, Class A

Thread Lubricant

MIL-T-5544

Water-Wash Detergent

GE Spec MID-TD-0000-5 (Local Purchase)

Water-Wash Rinse Water

GE Spec MID-TD-0000-4 (Local Purchase)

24




WORK PACKAGE

TECHNICAL PROCEDURES GENERAL MAINTENANCE PRACTICES (LEVEL 1 AND 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 5 ................... 0 6 Blank ............. 0 Alphabetical Index Page

Subject General Maintenance Practices.......................................................................................... Inspection Definitions. ........................................................................................................ Maintenance In Enclosure. .................................................................................................

4 4 3

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

GEK 105054 Volume II WP 002 00 1.


Introduction. This work package provides instructions for working in enclosure. It also addresses general maintenance practices that should be complied with during maintenance.

2.

Reference Material. Title

Number

Operation and Maintenance Manual, Volume I Introduction General Maintenance Practices Operation and Maintenance Manual, Volume II Illustrated Parts Breakdown

GEK 105054 Chapter 1 Chapter 10 GEK 105054 GEK 105055

CAUTION IF SHIPPING DOCUMENTATION OR PART NUMBER DOES NOT MATCH PART IDENTIFICATION AS SHOWN IN IPB, CONTACT YOUR CSM TO VERIFY/VALIDATE PART NUMBER APPLICABILITY BEFORE INSTALLATION OR DAMAGE TO GAS GENERATOR/GAS TURBINE COMPONENTS MAY OCCUR. 3.

Support Equipment. None required.

4.

Consumable Material.

5.

Nomenclature

Part No./Specification

Shop Rags

Local Purchase





Maintenance In Enclosure. a.

Comply with safety summary items listed in GEK 105054, Chapter 1, while in enclosure.

b.

Prepare engine and enclosure for maintenance as follows: (1)

Turn off and tag out fire extinguishing system per packager’s manual.

(2)

Turn off and tag out fuel supply per packager’s manual.

(3)

Turn off and tag out electrical service per packager’s manual.

(4)

If disconnecting lubricating oil lines, turn off and tag out lubricating oil supply per packager’s manual.

(5)

Ensure enclosure is free of fuel or natural gas. Refer to packager’s manual.

(6)

Ensure adequate ventilation of enclosure is provided. Refer to packager’s manual.

(7)

If applicable, open enclosure door. Ensure door cannot accidentally close.

(8)

Turn on enclosure lights per packager’s manual.

(9)

Visually inspect enclosure floor and horizontal surfaces for evidence of fluid leakage. If evidence of fluid leakage is seen, do the following: (a) Consult appropriate work package for area that could be source of fluid. (b) Consult packager’s manual if source of leakage is not covered by maintenance procedures in GEK 105054, Volume II.

(10) Comply with all packager provided work and safety instructions. c.

After completion of maintenance, return engine to service as follows: (1)

Inspect enclosure for flammable materials, tools, or removed components. Remove materials from enclosure prior to beginning engine operation.

(2)

Inspect enclosure floor and horizontal surfaces for spilled fluids. Using shop rags, clean any spilled fluid.

(3)

If applicable, close and latch enclosure door shut.

(4)

Remove tag and turn on fire extinguishing system per packager’s manual.



7.

(5)

Remove tag and turn on fuel supply per packager’s manual.

(6)

Remove tag and turn on electrical service per packager’s manual.

(7)

Remove tag and turn on lubricating oil supply per packager’s manual if lubricating oil supply was turned off.

(8)

Comply with all packager provided instructions for returning engine to service.

General Maintenance Practices. a.

8.


Refer to GEK 105054, Chapter 10, for general maintenance practices.

Inspection Definitions. a.

The following definitions apply when inspecting components: (1)

Inspect. (a) Defines component to be inspected. (b) What discrepancies or conditions are to be noted during inspection.

(2)

On-Site Maximum Serviceable Limits. (a) Maximum departure from manufacturer’s established new equipment standards that will not materially reduce usability of component. (b) Maximum departure from manufacturer’s established new equipment standards that has no significant bearing upon effective use or operation of equipment between standard maintenance intervals.

(3)

On-Site Maximum Repairable Limits. (a) Defines extent of repair that can be performed on component to return it to serviceable condition. (b) No entry or dash in this column does not mean that component cannot be repaired, but, that to date, no repair procedure has been established. (c) Not repairable in this column means no feasible repair exists, and that no attempt should be made to repair component, under any circumstances, at current level of maintenance being accomplished.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (4)


On-Site Corrective Limits. (a) Defines if component should be replaced, and what applicable work package applies. (b) If repair materials, or component(s) to be replaced, are not available, it is permissible to replace next higher assembly.

5/(6 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES VARIABLE STATOR VANE ACTUATOR REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 10 ................. 0

Alphabetical Index Subject

Page

Variable Stator Vane Actuator Installation. ..................................................................... Variable Stator Vane Actuator Removal............................................................................

7 3


GEK 105054 Volume II WP 100 00 1.


Introduction. This work package contains instructions for removal and installation of variable stator vane (VSV) actuators.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Variable Stator Vane Torque Shaft Replacement Illustrated Parts Breakdown

GEK 105054 Chapter 7 GEK 105054 WP 002 00 WP 114 00 GEK 105055

Support Equipment Required. Nomenclature

Part No.

Assembly, Hydraulic Actuator Unit Fixture, Check - Actuator, Variable Stator

1C3569G2/G3 1C9403G01

Consumable Material. Nomenclature

Specification

Lubricating Oil

MIL-L-23699 or MIL-L-7808 736L680G01 R297P04 (Alt)

Safety Cable Safety Wire 5.

Expendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). Nomenclature

IPB Figure No. / Item

Preformed Packing Preformed Packing Preformed Packing Preformed Packing

57-9/58-5 57-12/58-8 57-11/58-11 57-14/58-13




Variable Stator Vane Actuator Removal. a.

Comply with all instructions contained in WP 002 00. NOTE There are two VSV actuators on the engine. Removal procedure is same for both.

b.

Disconnect linear variable differential transformer (LVDT) sensor cable (14, figure 1) from VSV actuator (7) as follows: WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

c.

(1)

Remove power to VSV actuator LVDT sensor cable (14) per packager’s manual.

(2)

Disconnect LVDT sensor cable (14) from electrical connector (13).

Disconnect oil hoses from VSV actuator (7) as follows: (1)

Place approved waste container under VSV actuator (7) to catch oil. WARNING

•

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

•

LIQUID IS HOT AND CAN CAUSE SEVERE BURNS. SKIN AND EYE PROTECTION IS REQUIRED TO PREVENT INJURY FROM SPLASH BURNS.

(2)

Tag and disconnect head-end hose (15) from tube reducer (23) installed in VSV actuator (7) head-end port. Drain excess oil into approved waste container.

(3)

Tag and disconnect drain hose (2) from oil drain can (22) connected to VSV actuator (7) rod-end port. Drain excess oil into approved waste container.

(4)

Tag and disconnect rod-end hose (1) from fitting retainer (18) installed in drain can (22). Drain excess oil into approved waste container.




Figure 1. VSV Actuator Replacement (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. VSV Actuator Replacement (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



d.

•

Replacement VSV actuators do not provide connecting hardware for VSV actuators. Retain drain can, tube nipple, fitting retainer, and tube reducer for reuse, if VSV actuator is to be replaced.

•

Do not disturb rod-end jamnut while removing VSV actuator.

Remove oil hose connecting hardware from VSV actuator (7) as follows: (1)

Remove hardware from VSV actuator (7) rod-end port as follows: (a) Remove safety-wire that secures sleeve nut (21). (b) Disconnect sleeve nut (21) that secures drain can (22) onto VSV actuator (7) rod-end port. (c) Remove drain can (22). Remove and discard preformed packing (20). (d) Remove fitting retainer (18) from tube nipple (17). Remove and discard preformed packing (19). (e) Remove tube nipple (17) from VSV actuator (7) rod-end port. Remove and discard preformed packing (16).

(2) e.

f.

Remove tube reducer (23) from VSV actuator (7) head-end port. Remove and discard preformed packing (24).

Remove VSV actuator (7) from high pressure compressor (HPC) stator case as follows: (1)

Remove bolt (4), flat washer (5), actuator lug sleeve bushing (25), and self-locking nut (6) that connect VSV actuator (7) rod to VSV torque shaft assembly (3).

(2)

Remove bolt (8), flat washer (9), flat washer (26), and self-locking nut (10) that connect VSV actuator (7) to mounting bracket (12) on HPC stator case.

(3)

Remove VSV actuator (7) from engine. Cap all openings with shipping covers.

If required, remove mounting bracket from HPC stator case as follows: (1)

Remove safety wire and four bolts (11) that secure mounting bracket (12) to HPC stator case.

(2)

Remove mounting bracket (12).




Variable Stator Vane Actuator Installation. NOTE Check VSV actuator length only when actuator rod-end adjustment is disturbed during removal or installation. a.

Check VSV actuator (7) length as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. CAUTION

(1)

•

USE HYDRAULIC ACTUATOR UNIT, 1C3569G3, WITH ENGINES THAT USE LUBRICATING OIL, MIL-L-23699.

•


•

DO NOT INTERMIX LUBRICATING OILS, MIL-L-7808 AND MIL-L-23699, OR VSV ACTUATOR FAILURE WILL OCCUR.

Connect hydraulic actuator unit, 1C3569, to VSV actuator (7). WARNING

SERIOUS INJURY CAN OCCUR WHEN APPLYING HYDRAULIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS. CAUTION MAINTAIN 250 PSI (1724 KPA), TO KEEP VSV ACTUATOR FULLY EXTENDED WHEN ADJUSTING ROD-END. (2)

Using hydraulic actuator unit, 1C3569, supply 250 psi (1724 kPa) to extend VSV actuator (7) to full length.

(3)

Remove safety wire and loosen jamnut (figure 2) that secures VSV actuator rod-end.

(4)

Adjust VSV actuator rod-end so actuator slides freely onto fixture, 1C9403.




Figure 2. VSV Actuator Length Check

b.

(5)

Tighten jamnut to secure VSV actuator rod-end. Tighten jamnut to 110-130 lb in. (12.4-14.3 N⋅m) of torque and safety-wire.

(6)

Release pressure from hydraulic actuator supply unit, 1C3569, and VSV actuator.

If required, install mounting bracket (12, figure 1) onto HPC stator case as follows: CAUTION ENSURE MOUNTING BRACKET IS POSITIONED CORRECTLY ON HPC STATOR CASE WHEN REINSTALLING. INCORRECT POSITIONING WILL RESULT IN POSSIBLE OFF-SCHEDULE VSV OPERATION. (1)

Align mounting bracket (12) with boss on HPC stator case.

(2)

Apply thread lubricant to four bolts (11).

(3)

Using four bolts (11), secure mounting bracket (12) to HPC stator case. Tighten bolts to 380-420 lb in. (43-47.4 N⋅m) of torque and safety-wire.



d.


Install VSV actuator (7) onto HPC stator case as follows: (1)

Apply thread lubricant to bolt (4).

(2)

Using bolt (4), actuator lug sleeve bushing (25), flat washer (5), and selflocking nut (6) (washer under nut), connect VSV actuator rod to VSV torque shaft (3). Tighten bolt to 205-225 lb in. (23.2-25.4 N⋅m) of torque.

(3)

Apply thread lubricant to bolt (8).

(4)

Using bolt (8), flat washer (9) under bolthead, and flat washer (26) under self-locking nut (10), connect VSV actuator (7) to mounting bracket (12) on HPC stator case. Tighten bolt to 110-120 lb in. (12.4-13.5 N⋅m) of torque.

If required, install oil hose connecting hardware onto VSV actuator (7) as follows: (1)

Install connecting hardware onto VSV actuator (7) rod-end port as follows: WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Lubricate preformed packings (16, 19, and 20) with lubricating oil. (b) Install preformed packing (16) onto tube nipple (17). Install tube nipple into VSV actuator (7). Tighten tube nipple to 135-155 lb in. (15.3-17.5 N⋅m) of torque. (c) Install preformed packing (19) onto fitting retainer (18). Install fitting retainer onto tube nipple (17). Tighten retainer to 135-155 lb in. (15.3-17.5 N⋅m) of torque. (d) Install preformed packing (20) into sleeve nut (21). (e) Install drain can (22) over fitting retainer (18) and tube nipple (17). Hand-tighten sleeve nut (21) and safety-wire. (2)

Install tube reducer (23) into VSV actuator (7) head-end port as follows: (a) Lubricate preformed packing (24) with lubricating oil. (b) Install preformed packing (24) onto tube reducer (23). (c) Install tube reducer (23) into VSV actuator (7) head-end port. Tighten tube reducer to 135-155 lb in. (15.3-17.5 N⋅m) of torque. 9


GEK 105054 Volume II WP 100 00 e.

f.


Connect oil hoses onto VSV actuator (7) as follows: (1)

Connect head-end hose (15) to tube reducer (23). Tighten hose fitting to 270-300 lb in. (30.5-33.9 N⋅m) of torque.

(2)

Connect drain hose (2) to drain can (22). Tighten hose fitting to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

(3)

Connect rod-end hose (1) to fitting retainer (18). Tighten hose fitting to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

Connect LVDT sensor cable (14) as follows: WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. (1)

Connect LVDT sensor cable (14) to electrical connector (13).

(2)

Tighten LVDT sensor cable connector to 20 degrees beyond finger-tight.

(3)

Reconnect power to VSV actuator LVDT sensor cable (14) per packager’s manual.

g.

Motor engine per GEK 105054, Chapter 7. Actuate VSV system to purge air.

h.

Check VSV system fluid connectors for leakage.




WORK PACKAGE

TECHNICAL PROCEDURES FUEL SYSTEM REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 6 ................... 0 Alphabetical Index Page

Subject Fuel System Configuration. ................................................................................................

3


GEK 105054 Volume II WP 101 00 1.


Introduction. This work package provides fuel system configuration information, including steam or water injection for nitrogen oxide (NOx) suppression, for LM2500+ SAC gas turbines and gas generators.

2.


Number

Operation and Maintenance Manual, Volume II Liquid Fuel Nozzle Replacement Liquid Fuel With Steam Injection Fuel Nozzle Replacement Liquid Fuel With Water Injection Fuel Nozzle Replacement Natural Gas Fuel Nozzle Replacement Natural Gas With Steam Injection Fuel Nozzle Replacement Natural Gas With Water Injection Fuel Nozzle Replacement Dual Fuel Nozzle Replacement Dual Fuel With Steam Injection Fuel Nozzle Replacement Liquid Fuel Manifold Replacement Natural Gas Fuel Manifold Replacement Dual Liquid Manifold Replacement Steam Manifold Replacement Water Manifold Replacement Fuel System Inspection

GEK 105054 SWP 101 01

3.


4.

Consumable Material. None required.

5.


SWP 101 02 SWP 101 03 SWP 101 04 SWP 101 05 SWP 101 06 SWP 101 07 SWP 101 08 SWP 101 09 SWP 101 10 SWP 101 11 SWP 101 12 SWP 101 13 WP 415 00




Fuel System Configuration. a.

Refer to tables 1, 2, and 3 for appropriate work packages for replacement of fuel system components.

b.

After maintenance is complete, leak check and inspect fuel systems per WP 415 00.

Table 1. LM2500+ SAC Fuel System Configurations for Gas Turbines with Six-Stage Power Turbine Fuel System Type Configuration

Power Turbine Type


Model Number

Applicable SWP

Gas turbine

Liquid fuel

Six-stage

None

7LM2500-PK-ML

SWP 101 01 SWP 101 09

Gas turbine

Liquid fuel

Six-stage

Steam

7LM2500-PK-MLS

SWP 101 02 SWP 101 10 SWP 101 11

Gas turbine

Liquid fuel

Six-stage

Water

7LM2500-PK-MLW

SWP 101 03 SWP 101 11

Gas turbine

Gas fuel

Six-stage

None

7LM2500-PK-MG

SWP 101 04 SWP 101 10

Gas turbine

Gas fuel

Six-stage

Steam

7LM2500-PK-MGS

SWP 101 05 SWP 101 10 SWP 101 12

Gas turbine

Gas fuel

Six-stage

Water

7LM2500-PK-MGW

SWP 101 06 SWP 101 10 SWP 101 13

Gas turbine

Dual fuel

Six-stage

None

7LM2500-PK-MD

SWP 101 07 SWP 101 10 SWP 101 11

Gas turbine

Dual fuel

Six-stage

Steam

7LM2500-PK-MDS

SWP 101 08 SWP 101 10 SWP 101 11 SWP 101 12

Gas turbine

Dual fuel

Six-stage

Water

7LM2500-PK-MDW

SWP 101 07 SWP 101 10 SWP 101 11 3




Table 2. LM2500+ SAC Fuel System Configurations for Gas Turbines with Two-Stage Power Turbine Fuel System Type Configuration

Power Turbine Type

NOx Suppresion Method

Model Number

Applicable SWP

Gas turbine

Liquid fuel

Two-stage

None

7LM2500-PV-ML

SWP 101 01 SWP 101 09

Gas turbine

Liquid fuel

Two-stage

Steam

7LM2500-PV-MLS

SWP 101 02 SWP 101 10 SWP 101 11

Gas turbine

Liquid fuel

Two-stage

Water

7LM2500-PV-MLW

SWP 101 03 SWP 101 11

Gas turbine

Gas fuel

Two-stage

None

7LM2500-PV-MG

SWP 101 04 SWP 101 10

Gas turbine

Gas fuel

Two-stage

Steam

7LM2500-PV-MGS

SWP 101 05 SWP 101 10 SWP 101 12

Gas turbine

Gas fuel

Two-stage

Water

7LM2500-PV-MGW

SWP 101 06 SWP 101 10 SWP 101 13

Gas turbine

Dual fuel

Two-stage

None

7LM2500-PV-MD

SWP 101 07 SWP 101 10 SWP 101 11

Gas turbine

Dual fuel

Two-stage

Steam

7LM2500-PV-MDS

SWP 101 08 SWP 101 10 SWP 101 11 SWP 101 12

Gas turbine

Dual fuel

Two-stage

Water

7LM2500-PV-MDW

SWP 101 07 SWP 101 10 SWP 101 11



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. LM2500+ SAC Fuel System Configurations-Gas Generators Fuel System Type Configuration

Power Turbine Type


Model Number

Applicable SWP

Gas generator

Liquid fuel

OEM

None

7LM2500-GK-ML

SWP 101 01 SWP 101 09

Gas generator

Liquid fuel

OEM

Steam

7LM2500-GK-MLS

SWP 101 02 SWP 101 10 SWP 101 11

Gas generator

Liquid fuel

OEM

Water

7LM2500-GK-MLW

SWP 101 03 SWP 101 11

Gas generator

Gas fuel

OEM

None

7LM2500-GK-MG

SWP 101 04 SWP 101 10

Gas generator

Gas fuel

OEM

Steam

7LM2500-GK-MGS

SWP 101 05 SWP 101 10 SWP 101 12

Gas generator

Gas fuel

OEM

Water

7LM2500-GK-MGW

SWP 101 06 SWP 101 10 SWP 101 13

Gas generator

Dual fuel

OEM

None

7LM2500-GK-MD

SWP 101 07 SWP 101 10 SWP 101 11

Gas generator

Dual fuel

OEM

Steam

7LM2500-GK-MDS

SWP 101 08 SWP 101 10 SWP 101 11

Gas generator

Dual fuel

OEM

Water

7LM2500-GK-MDW

SWP 101 07 SWP 101 10 SWP 101 11

Gas generator

Liquid fuel

None

None

7LM2500-GV-ML

SWP 101 01 SWP 101 09

Gas generator

Liquid fuel

None

Steam

7LM2500-GV-MLS

SWP 101 02 SWP 101 10 SWP 101 11

Gas generator

Liquid fuel

None

Water

7LM2500-GV-MLW

SWP 101 03 SWP 101 11




Table 3. LM2500+ SAC Fuel System Configurations-Gas Generators - (Cont.) Fuel System Type Configuration

Power Turbine Type


Model Number

Applicable SWP

Gas generator

Gas fuel

None

None

7LM2500-GV-MG

SWP 101 04 SWP 101 10

Gas generator

Gas fuel

None

Steam

7LM2500-GV-MGS

SWP 101 05 SWP 101 10 SWP 101 12

Gas generator

Gas fuel

None

Water

7LM2500-GV-MGW

SWP 101 06 SWP 101 10 SWP 101 13

Gas generator

Dual fuel

None

None

7LM2500-GV-MD

SWP 101 07 SWP 101 10 SWP 101 11

Gas generator

Dual fuel

None

Steam

7LM2500-GV-MDS

SWP 101 08 SWP 101 10 SWP 101 11 SWP 101 12

Gas generator

Dual fuel

None

Water

7LM2500-GV-MDW

SWP 101 07 SWP 101 10 SWP 101 11


GEK 105054 Volume II SWP 101 01


SUBORDINATE WORK PACKAGE

TECHNICAL PROCEDURES LIQUID FUEL NOZZLE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE SWP PAGES Total Number of Pages in this SWP is 10 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.

1 - 9 ................... 0 10 Blank ........... 0 Alphabetical Index Page

Subject Fuel Nozzle Installation...................................................................................................... Fuel Nozzle Removal...........................................................................................................

7 3


GEK 105054 Volume II SWP 101 01 1.


Introduction. This work package provides instructions for removal and installation of fuel nozzles used with liquid fuel system.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Inspection Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 415 00 GEK 105055

Support Equipment. Nomenclature

Part No.

Adapter Set-Fuel Manifold

2C6081G06



Grease Isopropyl Alcohol Marking Pen

MIL-G-23827 Fed Spec TT-I-735 Sharpie T.E.C. or Action Marker Local Purchase Local Purchase 736L680G01 R297P04 (Alt)

Masking Tape Plastic Bags Safety Cable Safety Wire 5.


IPB Figure No./Item

Preformed Packing Metal Seal Ring Metal Seal

37-33 37-9 37-31




Fuel Nozzle Removal. a.

Comply with all instructions contained in WP 002 00. WARNING

•

FUEL IN LIQUID, VAPOR, OR MIST FORM IS FLAMMABLE, IRRITATING TO THE SKIN AND RESPIRATORY TRACT, AND POISONOUS IN THE DIGESTIVE TRACT. REMOVE SATURATED CLOTHING, WASH SKIN WELL, DON'T SWALLOW LIQUID, AND DON'T BREATHE MIST OR VAPOR.

•

FUEL SYSTEM COULD BE PRESSURIZED. USE CARE TO PREVENT INJURY WHEN DISCONNECTING LINES. NOTE

There are 30 fuel nozzle assemblies located on the compressor rear frame (CRF). Removal is same for all. b.

Remove all safety wire from fuel nozzle assembly.

c.

If required, depressurize fuel system per packager’s manual.

d.

Disconnect shrouded tube (1, figure 1) from fuel manifold as follows: (1)

Using marking pen, position mark shrouded tube (1) engine location.

(2)

Using wrench, 2C6081P16 (figure 2), apply counterforce to shrouded tube (1, figure 1) as shown in figure 2. NOTE

•

Wrench, 2C6081P10, is used on shrouded fuel tube numbers 13, 14, 16, and 17.

•

Wrench, 2C6081P13, is used on shrouded fuel tubes at all non-specified locations.

•

Wrench, 2C6081P15, is used on shrouded fuel tubes at split-line of high pressure compressor (HPC) casing.

(3)

Break torque on coupling nut (11, figure 1) using wrench, 2C6081P10, P13, or P15.

(4)

Remove wrenches and loosen coupling nut (11) by hand.




Figure 1. Fuel Nozzle and Fuel Tubes




Figure 2. Fuel Manifold Adapter Set, 2C6081


GEK 105054 Volume II SWP 101 01 e.

f.

g.


Disconnect shrouded tube (1) from fuel nozzle (4) as follows: (1)

Using marking pen, position mark fuel nozzle (4) engine location.

(2)

Disconnect coupling nut (8) from fuel nozzle (4).

(3)

Move shrouded tube forward to expose fuel tube (7) coupling nuts (10).

Remove fuel tube (7) from fuel nozzle (4) and fuel manifold (14) as follows: (1)

Loosen coupling nuts (10) and slide forward against stops (9) on fuel tube (7).

(2)

Remove shrouded tube (1) and fuel tube (7) from fuel nozzle (4) and fuel manifold (14).

(3)

Remove metal seal (6) from fuel tube (7). Discard metal seal.

(4)

Place shrouded tube (1) and fuel tube (7) in plastic bag for storage.

Remove fuel nozzle as follows: (1)

If more than one nozzle is to be removed, mark position of fuel nozzle (4) to be removed using marking pen.

(2)

Remove three bolts (3) used to secure fuel nozzle (4) to CRF. CAUTION

USE EXTREME CARE WHEN REMOVING FUEL NOZZLE FROM COMBUSTOR TO ENSURE FUEL NOZZLE TIP IS NOT DAMAGED. (3)

Remove fuel nozzle (4) from CRF fuel nozzle mounting boss. Discard metal seal ring (5).

(4)

Remove preformed packing (2) from fuel nozzle (4). Discard preformed packing.

(5)

Place fuel nozzle in plastic bag for storage.

h.

Using masking tape, cover opening in CRF.

i.

Repeat steps d. through h. for all fuel nozzles to be removed.

j.

Inspect fuel nozzles per WP 415 00.




Fuel Nozzle Installation. CAUTION REMOVE MASKING TAPE ONE PORT AT A TIME TO MINIMIZE POSSIBILITY OF FOREIGN OBJECTS ENTERING ENGINE. a.

Remove masking tape from fuel nozzle port in CRF. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Using isopropyl alcohol, clean fuel nozzle mounting boss on CRF.

c.

Install fuel nozzle (4, figure 1) as follows: (1)

Place metal seal ring (5) onto CRF fuel nozzle mounting boss. CAUTION

USE EXTREME CARE WHEN INSTALLING FUEL NOZZLE INTO COMBUSTOR TO ENSURE FUEL NOZZLE TIP IS NOT DAMAGED.

d.

(2)

Install fuel nozzle (4) into CRF. Ensure fuel nozzle and metal seal ring (5) are properly seated on CRF fuel nozzle mounting boss.

(3)

Using three bolts (3), secure fuel nozzle (4) to CRF fuel nozzle mounting boss. Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. Safety-wire bolts.

(4)

Using grease, lubricate preformed packing (2).

(5)

Install preformed packing (2) onto fuel nozzle (4).

Install fuel tube (7) onto fuel nozzle (4) and fuel manifold (14) as follows: NOTE Grease is used to hold metal seal in place during assembly of shrouded tube to fuel manifold. (1)

Using grease, coat both sides of metal seal (6).

(2)

Place metal seal onto fuel manifold (14) fuel port.

(3)

Apply grease to nut-to-ferrule interfaces for fuel tube (7).




(4)

Using coupling nut (10), install fuel tube (7) onto fuel manifold (14). Tighten coupling nut finger-tight.

(5)

Using coupling nut (10), install fuel tube (7) onto fuel nozzle (4). Tighten coupling nut finger-tight.

(6)

Repeat steps (1) through (5) for all fuel nozzles to be installed. CAUTION

DO NOT OVER-TORQUE COUPLING NUT OR, DAMAGE TO FUEL FEEDER TUBES MAY RESULT. (7)

Triple tighten coupling nuts (10) as follows: (a) Tighten coupling nuts to 120-135 lb in. (13.6-15.2 N⋅m) of torque at each joint sequentially in a clockwise direction aft looking forward (ALF). (b) Loosen until coupling nut is free running and retighten to 120-135 lb in. (13.6-15.2 N⋅m) of torque at each joint sequentially in a clockwise direction ALF. (c) Check coupling nut by reapplying 120-135 lb in. (13.6-15.2 N⋅m) of torque at each joint sequentially in a clockwise direction ALF. NOTE

e.

•

Wrench, 2C6081P10, is used on shrouded fuel tube numbers 13, 14, 16, and 17.

•

Wrench, 2C6081P13, is used on shrouded fuel tubes at all nonspecified locations.

•

Wrench, 2C6081P15, is used on shrouded fuel tubes at split-line of high pressure compressor (HPC) casing.

Install shrouded tube (1) onto fuel nozzle (4) and fuel manifold (14) as follows: CAUTION ENSURE METAL SEAL IS PROPERLY SEATED PRIOR TO SLIDING SHROUDED TUBE AFT TO AVOID DAMAGE TO METAL SEAL. NOTE Ensure alignment pin (12) in shrouded tube (1) engages alignment slot (13) in fuel manifold (14) during installation. (1)

Slide shrouded tube (1) aft over fuel tube (7) until seated onto fuel nozzle (4). Tighten coupling nut (8) hand-tight.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (2) f.


Using wrench, 2C6081P16 (figure 2), apply counterforce to shrouded tube (1).

Repeat steps e.(1) through e.(2) for all fuel nozzles to be installed. CAUTION DO NOT OVER-TORQUE COUPLING NUT OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT.

g.

Final tighten fuel tube coupling nut (11, figure 1) using wrench, 2C6081P10, P13, or P15. Tighten coupling nut to 360-500 lb in. (40.7-56.4 N⋅m) of torque.

h.

Perform a leak check to fuel system after installation per Chapter 7-3.7.





TECHNICAL PROCEDURES LIQUID FUEL WITH STEAM INJECTION FUEL NOZZLE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 8 ................... 0


Page

Fuel Nozzle Installation...................................................................................................... Fuel Nozzle Removal...........................................................................................................

6 3




Introduction. This work package provides instructions for the removal and installation of fuel nozzles used with liquid fuel systems that utilize steam injection for nitrogen oxide (NOx) suppression.

2.


Number


GEK 105054 WP 002 00 WP 415 00 GEK 105055

3.


4.







IPB Figure No./Item

Metal Seal Ring

40-31






b.

•


•

FUEL SYSTEM COULD BE PRESSURIZED. USE CARE TO PREVENT INJURY WHEN DISCONNECTING LINES.

Depressurize fuel and steam systems per packager’s manual. NOTE There are 30 fuel nozzle assemblies located on the compressor rear frame (CRF). 20 steam tubes (12, figure 1), six steam tubes (14), and four steam tubes (13) are used to connect the fuel nozzles to the steam manifold. Removal procedure is the same for all.

c.

Disconnect steam tube (12, 13, or 14) from steam manifold (15) as follows: (1)

Using marking pen, position mark steam tube (12, 13, or 14) engine fuel nozzle location.

(2)

Loosen coupling nut (16) that secures steam tube (12, 13, or 14) to steam manifold (15).

d.

Loosen coupling nut (17) that secures steam tube (12, 13, or 14) to fuel nozzle (1). Remove steam tube.

e.

Place removed steam tube (12, 13, or 14) in plastic bag for storage.

f.

Disconnect liquid tubes (4 and 5) from liquid manifolds (6 and 7) as follows:

g.

(1)

Using marking pen, position mark liquid tubes (4 and 5) engine location.

(2)

Loosen coupling nuts (8 and 9) that secure liquid tubes (4 and 5) to liquid manifolds (6 and 7).

Loosen coupling nuts (10 and 11) that secure liquid tubes (4 and 5) to fuel nozzle (1). Remove liquid tubes.




Figure 1. Fuel Nozzle and Liquid Fuel/Steam Manifolds (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Fuel Nozzle and Liquid/Steam Manifolds (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



h.

Place removed liquid tubes (4 and 5) in plastic bag for storage.

i.

Remove fuel nozzle (1) from CRF as follows: (1)

Remove safety wire that secures three bolts (3) to fuel nozzle.

(2)

Remove three bolts (3) that secure fuel nozzle (1) to CRF fuel nozzle mounting boss. CAUTION

USE EXTREME CARE WHEN REMOVING FUEL NOZZLE FROM COMBUSTOR TO ENSURE FUEL NOZZLE TIP IS NOT DAMAGED.

7.

(3)

Remove fuel nozzle (1) from CRF fuel nozzle mounting boss.

(4)

Remove metal seal ring (2) and discard.

(5)

Place fuel nozzle (1) in plastic bag for storage.

j.


k.

Repeat steps c. through j. for all fuel nozzles to be removed.

l.

Inspect fuel nozzles per WP 415 00



b.


c.


Place metal seal ring (2) onto CRF fuel nozzle mounting boss.




CAUTION USE EXTREME CARE WHEN INSTALLING FUEL NOZZLE INTO COMBUSTOR TO ENSURE FUEL NOZZLE TIP IS NOT DAMAGED.

d.

e.

f.

g.

h.

(2)


(3)


Install liquid tubes (4 and 5) onto liquid manifolds (6 and 7) as follows: (1)

Using grease, lubricate liquid manifolds (6 and 7) nipples where liquid tubes (4 and 5) connect.

(2)

Align liquid tubes (4 and 5) coupling nuts (8 and 9) with liquid manifolds (6 and 7) nipples. Tighten coupling nuts hand-tight.

Install liquid tubes (4 and 5) onto fuel nozzle (1) as follows: (1)

Using grease, lubricate fuel nozzle (1) nipples where liquid tubes (4 and 5) connect.

(2)

Align liquid tubes (4 and 5) coupling nuts (10 and 11) with fuel nozzle (1) nipple. Tighten coupling nuts hand-tight.

Install steam tubes (12, 13, or 14) onto steam manifold (15) as follows: (1)

Using grease, lubricate steam manifold (15) nipple where steam tubes (12, 13, and 14) connect.

(2)

Align steam tubes (12, 13, or 14) coupling nut (16) with steam manifold (15) nipple. Tighten coupling nut hand-tight.

Install steam tubes (12, 13, or 14) onto fuel nozzle (1) as follows: (1)

Using grease, lubricate fuel nozzle (1) nipple where steam tubes (12, 13, and 14) connect.

(2)

Align steam tubes (12, 13, or 14) coupling nut (17) with fuel nozzle (1) nipple. Tighten coupling nut hand-tight.

Repeat steps a. through g. for all fuel nozzles to be installed.




DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO STEAM TUBES MAY RESULT. i.

Triple tighten coupling nuts (16 and 17) as follows: (1)

Tighten coupling nuts to 75-91 lb ft (101.7-123.3 N⋅m) of torque.

(2)

Break torque on coupling nuts and retighten to 75-91 lb ft (101.7-123.3 N⋅m) of torque.

(3)

Break torque on coupling nuts and final tighten to 75-91 lb ft (101.7-123.3 N⋅m) of torque. CAUTION

DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT. j.


Tighten coupling nuts to 120-135 lb in. (13.6-15.2 N⋅m) of torque at each joint sequentially in a clockwise direction aft looking forward (ALF).

(2)

Loosen until coupling nut is free running and retighten to 120-135 lb in. (13.6-15.2 N⋅m) of torque at each joint sequentially in a clockwise direction ALF.

(3)

Check coupling nut by reapplying 120-135 lb in. (13.6-15.2 N⋅m) of torque at each joint sequentially in a clockwise direction ALF. CAUTION

DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT. k.

l.


Tighten coupling nut (10) to 120-135 lb in. (13.6-15.2 N⋅m) of torque and tighten coupling nut (11) to 160-180 lb in. (18.1-20.3 N⋅m) of torque at each joint sequentially in a clockwise direction aft looking forward (ALF).

(2)

Break torque on coupling nuts (10 and 11). Retighten coupling nut (10) to 120-135 lb in. (13.6-15.2 N⋅m) of torque and retighten coupling nut (11) to 160-180 lb in. (18.1-20.3 N⋅m) of torque at each joint sequentially in a clockwise direction ALF.

(3)

Check coupling nuts (10) by reapplying 120-135 lb in. (13.6-15.2 N⋅m) of torque and coupling nuts (11) by reapplying 160-180 lb in. (18.1-20.3 N⋅m) of torque at each joint sequentially in a clockwise direction ALF.






TECHNICAL PROCEDURES LIQUID FUEL WITH WATER INJECTION FUEL NOZZLE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 6 ................... 0


Page


5 3




Introduction. This work package provides instructions for the removal and installation of fuel nozzles used with liquid fuel systems that utilize water injection for nitrogen oxide (NOx) suppression.

2.


Number


GEK 105054 WP 002 00 WP 415 00 GEK 105055

3.


4.







IPB Figure No./Item

Metal Seal Ring

41-17






b.

•


•


Depressurize fuel system per packager’s manual. Depressurize water system per packager’s manual. NOTE There are 30 fuel nozzle assemblies located on the compressor rear frame (CRF). Removal procedure is same for all.

c.

Disconnect secondary and primary fuel feeder tubes (3 and 4, figure 1) from primary and secondary fuel manifolds (9 and 10) as follows: (1)

Using marking pen, position mark secondary and primary fuel feeder tubes (3 and 4) engine location.

(2)

Loosen coupling nuts (11 and 12) that secures secondary and primary fuel feeder tubes (3 and 4) to primary and secondary fuel manifolds (9 and 10).

d.

Loosen coupling nuts (5 and 6) that secures secondary and primary fuel feeder tubes (3 and 4) to fuel nozzle (1). Remove fuel feeder tubes.

e.

Place removed secondary and primary fuel feeder tubes (3 and 4) in plastic bag for storage.

f.



(2)




(4)


(5)

Place fuel nozzle (1) in plastic bag for storage. 3




Figure 1. Fuel Nozzle and Liquid Fuel/Water Manifolds 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


7.

g.


h.

Repeat steps c. through g. for all fuel nozzles to be removed.

i.





b.


c.



USE EXTREME CARE WHEN INSTALLING FUEL NOZZLE INTO COMBUSTOR TO ENSURE FUEL NOZZLE TIP IS NOT DAMAGED.

d.

(2)


(3)


Install secondary and primary fuel feeder tubes (3 and 4) onto primary and secondary fuel manifolds (9 and 10) as follows: (1)

Using grease, lubricate primary and secondary fuel manifolds (9 and 10) nipples where fuel feeder tubes (3 and 4) connect.

(2)

Align secondary and primary fuel feeder tubes (3 and 4) coupling nuts (11 and 12) with primary and secondary fuel manifolds (9 and 10) nipple. Tighten coupling nuts hand-tight.



f.


Install secondary and primary fuel feeder tubes (3 and 4) onto fuel nozzle (1) as follows: (1)

Using grease, lubricate fuel nozzle (1) nipples where secondary and primary fuel feeder tubes (3 and 4) connect.

(2)

Align secondary and primary fuel feeder tubes (3 and 4) coupling nuts (5 and 6) with fuel nozzle (1) nipples. Tighten coupling nuts hand-tight.

Repeat steps a. through e. for all fuel nozzles to be installed. CAUTION DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT.

g.

Triple tighten coupling nuts (6, 11 and 12) as follows: (1)


(2)


(3)


DO NOT OVER-TORQUE COUPLING NUTS, DAMAGE TO FUEL FEEDER TUBES MAY RESULT. h.

i.

Triple tighten coupling nut (5) as follows: (1)

Tighten coupling nut to 160-180 lb in. (18.1-20.3 N⋅m) of torque at each joint sequentially in a clockwise direction aft looking forward (ALF).

(2)


(3)

Check coupling nut by reapplying 160-180 lb in. (18.1-20.3 N⋅m) of torque at each joint sequentially in a clockwise direction ALF.

Perform leak check to fuel system after installation per Chapter 7-3.7.





TECHNICAL PROCEDURES NATURAL GAS FUEL NOZZLE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 6 ................... 0


Page


5 3




Introduction. This work package provides instructions for the removal and installation of fuel nozzles used with natural gas fuel system.

2.


Number


GEK 105054 WP 002 00 WP 415 00 GEK 105055

3.


4.







IPB Figure No./Item

Metal Seal Ring

35-19






b.

•


•


Depressurize fuel system per packager’s manual. NOTE There are 30 fuel nozzle assemblies located on the compressor rear frame (CRF). 20 fuel tubes (5, figure 1), six fuel tubes (6), and four fuel tubes (7) are used to connect the fuel nozzles (1) to the natural gas fuel manifold (4). Removal procedure is the same for all.

c.

d.

Disconnect fuel tube (5, 6, or 7) from natural gas fuel manifold (4) as follows: (1)

Using marking pen, position mark fuel tube (5, 6, or 7) engine location from number 1 at top dead center (TDC).

(2)

Loosen coupling nut (9) that secures fuel tube (5, 6, or 7) to natural gas fuel manifold (4).

Disconnect fuel tube (5, 6, or 7) from fuel nozzle (1) as follows: (1)

Using marking pen, position mark fuel nozzle (1) engine location from number 1 at TDC.

(2)

Loosen coupling nut (8) that secures fuel tube (5, 6, or 7) to fuel nozzle (1).

e.

Remove fuel tube (5, 6, or 7) and place in plastic bag for storage.

f.



(2)



Remove fuel nozzle (1) from CRF fuel nozzle mounting boss. 3




Figure 1. Fuel Nozzle and Natural Gas Fuel Manifold 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



7.

(4)


(5)

Place fuel nozzle in plastic bag for storage.

g.


h.

Repeat steps c. through g. for all fuel nozzles to be removed.

i.




b.

Using isopropyl alcohol, clean fuel nozzle mounting boss on CRF. NOTE Ensure fuel nozzles corresponding to fuel tubes (5, 6, and 7, figure 1) are located at the proper locations marked in paragraph 6., step d.(1).

c.

Install fuel nozzle (1) as follows: (1)


USE EXTREME CARE WHEN INSTALLING FUEL NOZZLE INTO COMBUSTOR TO ENSURE FUEL NOZZLE TIP IS NOT DAMAGED. (2)


(3)



GEK 105054 Volume II SWP 101 04 (4)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Using grease, lubricate fuel nozzle nipple where fuel tube (5, 6, or 7) will connect. NOTE

Ensure fuel tubes (5, 6, and 7) are located at the proper locations marked in paragraph 6., step c.(1). d.

Install fuel tube (5, 6, or 7) as follows: (1)

Using grease, lubricate natural gas fuel manifold (4) nipple where fuel tube (5, 6, or 7) will connect.

(2)

Align fuel tube (5, 6, or 7) coupling nut (9) with natural gas fuel manifold (4) nipple. Tighten coupling nut hand-tight.

(3)

Align fuel tube (5, 6, or 7) coupling nut (8) with fuel nozzle (1) nipple. Tighten coupling nut hand-tight.

e.

Repeat steps a. through d. for all fuel nozzles to be installed.

f.

Triple tighten coupling nuts (8 and 9) as follows:

g.

(1)

Tighten coupling nuts to 75-91 lb ft (101.7-123.4 N⋅m) of torque at each joint sequentially in a clockwise direction aft looking forward (ALF).

(2)

Loosen until coupling nut is free running and retighten to 75-91 lb ft (101.7-123.4 N⋅m) of torque at each joint sequentially in a clockwise direction ALF.

(3)

Check coupling nut by reapplying 75-91 lb ft (101.7-123.4 N⋅m) of torque at each joint sequentially in a clockwise direction ALF.






TECHNICAL PROCEDURES NATURAL GAS WITH STEAM INJECTION FUEL NOZZLE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


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Page No.

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Page No.

Change No.

1 - 8 ................... 0


Page


6 3




Introduction. This work package provides instructions for the removal and installation of fuel nozzles used with natural gas fuel systems that utilize steam injection for nitrogen oxide (NOx) suppression.

2.


Number


GEK 105054 WP 002 00 WP 415 00 GEK 105055

3.


4.







IPB Figure No./Item

Metal Seal Ring

39-22






b.

•


•

STEAM AND FUEL SYSTEM COULD BE PRESSURIZED. USE CARE TO PREVENT INJURY WHEN DISCONNECTING LINES.

Depressurize fuel and steam systems per packager’s manual. NOTE There are 30 fuel nozzle assemblies located on the compressor rear frame (CRF). 20 fuel tubes (5, figure 1), six fuel tubes (6), and four fuel tubes (7) are used to connect the fuel nozzles to the natural gas fuel manifold. Removal procedure is the same for all.

c.


Using marking pen, position mark fuel tube (5, 6, or 7) engine location of fuel nozzle.

(2)


d.

Loosen coupling nut (12) that secures fuel tube (5, 6, or 7) to fuel nozzle (1). Remove fuel tube.

e.

Place removed fuel tube (5, 6, or 7) in plastic bag for storage. NOTE There are two different steam tubes (10 and 14). Two steam tubes (14) are located at the T3 sensor locations. Removal is the same for all.

f.

Disconnect steam tube (10) from steam manifold as follows: (1)

Using marking pen, position mark steam tube (10 or 14) engine location of fuel nozzle.

(2)

Loosen coupling nut (9) that secures steam tube (10 or 14) to steam manifold (8).

g.

Loosen coupling nut (11) that secures steam tube (10 or 14) to steam manifold (8). Remove steam tube.

h.

Place removed steam tube (10 or 14) in plastic bag for storage. 3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Fuel Nozzle and Natural Gas/Steam Fuel Manifold (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Fuel Nozzle and Natural Gas/Steam Fuel Manifold (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 101 05 i.




(2)



7.

(3)


(4)


(5)


j.


k.


l.




b.


c.







d.

e.

f.

g.

(2)


(3)

Using three bolts (3), secure fuel nozzle (1) to CRF fuel nozzle mounting boss. Tighten bolts finger-tight.

Install steam tube (10 or 14) onto steam manifold (8) as follows: (1)

Using grease, lubricate steam manifold (8) nipple where steam tube (10 or 14) will connect.

(2)

Align steam tube (10 or 14) coupling nut (9) with steam manifold (8) nipple. Tighten coupling nut hand-tight.

Install steam tube (10 or 14) onto fuel nozzle (1) as follows: (1)

Using grease, lubricate fuel nozzle (1) nipple where steam tube (10 or 14) will connect.

(2)

Align steam tube (10 or 14) coupling nut (11) with fuel nozzle (1) nipple. Tighten coupling nut hand-tight.

Install fuel tube (5, 6, or 7) onto natural gas manifold as follows: (1)


(2)


Install fuel tube (5, 6, or 7) onto fuel nozzle (1) as follows: (1)

Using grease, lubricate fuel nozzle (1) nipple where fuel tube (5, 6, or 7) will connect.

(2)


h.

Repeat steps a. through g. for all fuel nozzles to be installed.

i.

Tighten three bolts securing fuel nozzle to CRF to 55-70 lb in. (6.3-7.9 N⋅m) of torque. Safety-wire bolts.




DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT. j.



(2)


(3)

Check coupling nut by reapplying 75-91 lb ft (101.7-123.4 N⋅m) of torque at each joint sequentially in a clockwise direction ALF. CAUTION

DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO STEAM TUBES MAY RESULT. k.

l.



(2)


(3)


Perform leak check on fuel system after installation per Chapter 7-3.7.





TECHNICAL PROCEDURES NATURAL GAS WITH WATER INJECTION FUEL NOZZLE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


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Page No.

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1 - 8 ................... 0


Page


6 3




Introduction. This work package provides instructions for the removal and installation of fuel nozzles used with natural gas fuel systems that utilize water injection for nitrogen oxide (NOx) suppression.

2.


Number


GEK 105054 WP 002 00 WP 415 00 GEK 105055

3.


4.







IPB Figure No./Item

Metal Seal Ring

38-14






b.

•


•


Depressurize fuel and water systems per packager’s manual. NOTE There are 30 fuel nozzle assemblies located on the compressor rear frame (CRF). 20 fuel tubes (5, figure 1), six fuel tubes (6), and four fuel tubes (7) are used to connect the fuel nozzles to the natural gas fuel manifold. Removal procedure is the same for all.

c.


Using marking pen, position mark fuel tube (5, 6, or 7) engine location.

(2)


d.


e.

Place removed fuel tube (5, 6, or 7) in plastic bag for storage.

f.

Disconnect water tube (9) from water manifold (8) as follows: (1)

Using marking pen, position mark water tube (9) engine location.

(2)

Remove safety wire and loosen coupling nut (10) that secures water tube (9) to water manifold (8).

g.

Loosen coupling nut (11) that secures water tube (9) to water manifold (8). Remove water tube.

h.

Place removed water tube (9) in plastic bag for storage.

i.



(2)

Remove three bolts (3) that secure fuel nozzle (1) to CRF fuel nozzle mounting boss. 3




Figure 1. Fuel Nozzle and Natural Gas Fuel/Water Manifold (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Fuel Nozzle and Natural Gas Fuel/Water Manifold (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.




7.

(3)


(4)


(5)


j.


k.


l.




b.


c.


Place metal ring seal (2) onto CRF fuel nozzle mounting boss. CAUTION

USE EXTREME CARE WHEN INSTALLING FUEL NOZZLE INTO COMBUSTOR TO ENSURE FUEL NOZZLE TIP IS NOT DAMAGED. (2)

Install fuel nozzle (1) into CRF. Ensure fuel nozzle and metal ring seal (2) are properly seated on CRF fuel nozzle mounting boss.

(3)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines d.

e.

f.

g.

h.


Install water tube (9) onto water manifold (8) as follows: (1)

Using grease, lubricate water manifold (8) nipple where water tube (9) will connect.

(2)

Align water tube (9) coupling nut (10) with water manifold (8) nipple. Tighten coupling nut hand-tight.

Install water tube (9) onto fuel nozzle (1) as follows: (1)

Using grease, lubricate fuel nozzle (1) nipple where water tube (9) will connect.

(2)

Align water tube (9) coupling nut (10) with fuel nozzle (1) nipple. Tighten coupling nut hand-tight.

Install fuel tube (5, 6, or 7) onto natural gas manifold as follows: (1)


(2)



Using grease, lubricate fuel nozzle (1) nipple where fuel tube (5, 6, or 7) will connect.

(2)


Repeat steps a. through g. for all fuel nozzles to be installed. CAUTION DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT.

i.


Tighten coupling nuts to 75-91 lb ft. (101.7-123.4 N⋅m) of torque at each joint sequentially in a clockwise direction aft looking forward (ALF).

(2)


(3)

Check coupling nut by reapplying 75-91 lb ft (101.7-123.4 N⋅m) of torque at each joint sequentially in a clockwise direction ALF. 7




DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO WATER TUBES MAY RESULT. j.

k.



(2)


(3)







TECHNICAL PROCEDURES DUAL FUEL NOZZLE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


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Page No.

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1 - 8 ................... 0


Page


6 3




Introduction. This work package provides instructions for the removal and installation of fuel nozzles used with the dual fuel system. The dual fuel system liquid manifolds can either provide liquid fuel from both liquid manifolds, or liquid fuel and water.

2.


Number


GEK 105054 WP 002 00 WP 415 00 GEK 105055

3.


4.







IPB Figure No./Item

Metal Seal Ring

36-37






b.

•


•


Depressurize fuel manifolds per packager’s manual. If required, depressurize water manifold per packager’s manual also. NOTE There are 30 fuel nozzle assemblies located on the compressor rear frame (CRF). 20 primary gas tubes (14, figure 1), six primary gas tubes (17), and four primary gas tubes (15) are used to connect the fuel nozzles to the natural gas fuel manifold. Removal procedure is the same for all.

c.

Remove primary gas tube (14, 15, or 17) from natural gas fuel manifold (16) and fuel nozzle (1) as follows: (1)

Using marking pen, position mark primary gas tube (14, 15, or 17) engine location.

(2)

Loosen two coupling nuts (12 and 13) on primary gas tube (14, 15, or 17).

(3)

Remove primary gas tube (14, 15, or 17).

(4)

Place primary gas tube (14, 15, or 17) in plastic bag for storage. NOTE

On dual fuel systems with water injection, secondary liquid fuel manifold (9) is used also as the water manifold. d.

Disconnect fuel tubes (3 and 4) from liquid fuel manifolds (8 and 9) and fuel nozzle (1) as follows: (1)

Using marking pen, position mark fuel tubes (3 and 4) engine location of fuel nozzles.

(2)

Disconnect two coupling nuts (10 and 11) from liquid fuel manifolds (8 and 9).

(3)

Disconnect two coupling nuts (2 and 5) from fuel nozzle (1).

(4)

Remove two fuel tubes (3 and 4).

(5)

Place two fuel tubes (3 and 4) into plastic bag for storage. 3




Figure 1. Duplex Dual Fuel System (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Duplex Dual Fuel System (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Remove fuel nozzle (1) as follows: (1)

Using marking pen, mark position of fuel nozzle (1) to be removed.

(2)

Cut safety wire and remove three bolts (7) used to secure fuel nozzle (1) to CRF. CAUTION


7.

(3)

Remove fuel nozzle (1) from CRF fuel nozzle mounting boss. Discard metal seal ring (6).

(4)


f.


g.

Repeat steps c. through f. for all fuel nozzles to be removed.

h.




b.


c.



(2)

Remove fuel nozzle from plastic bag.





d.

e.

f.

(3)


(4)


(5)

Using grease, lubricate fuel nozzle (1) nipple where fuel tubes (3 and 4) will connect.

Install fuel tubes (3 and 4) as follows: (1)

Using grease, lubricate liquid fuel manifold nipples where fuel tubes (3 and 4) will connect.

(2)

Remove fuel tubes (3 and 4) from plastic bag.

(3)

Align fuel tube coupling nuts (10 and 11) with liquid fuel manifold nipples. Tighten coupling nuts hand-tight.

(4)

Align fuel tube coupling nuts (2 and 5) with fuel nozzle (1) nipples. Tighten coupling nuts hand-tight.

Install natural gas fuel tube as follows: (1)

Using grease, lubricate natural gas fuel manifold (16) nipple where primary gas tube (14, 15, or 17) will connect.

(2)

Remove primary gas tube (14, 15, or 17) from plastic bag.

(3)

Align fuel tube coupling nut (13) with natural gas fuel manifold (16) nipple. Tighten coupling nut hand-tight.

(4)

Align fuel tube coupling nut (12) with fuel nozzle (1) nipple. Tighten coupling nut hand-tight.

Repeat steps a. through e. for all fuel nozzles to be installed. CAUTION DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT.

g.


Tighten coupling nuts to 120-135 lb in. (13.6-15.2 N⋅m) of torque at each joint sequentially in a clockwise direction aft looking forward (ALF). 7




(2)


(3)


DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT. h.

Triple tighten coupling nut (2) as follows: (1)


(2)


(3)


DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT. i.

j.



(2)


(3)







TECHNICAL PROCEDURES DUAL FUEL WITH STEAM INJECTION FUEL NOZZLE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Fuel Nozzle Installation...................................................................................................... Fuel Nozzle Removal...........................................................................................................

6 3




Introduction. This work package provides instructions for the removal and installation of fuel nozzles used with dual fuel systems that utilize steam injection for nitrogen oxide (NOx) suppression.

2.


Number


GEK 105054 WP 002 00 WP 415 00 GEK 105055

3.


4.







IPB Figure No./Item

Metal Seal Ring

42-21






b.

•


•


Depressurize fuel system per packager’s manual. Depressurize steam system per packager’s manual. NOTE There are 30 fuel nozzle assemblies located on the compressor rear frame (CRF). Removal procedure is same for all.

c.

Disconnect steam tube (10, figure 1) from steam manifold (8) as follows: (1)

Using marking pen, position mark steam tube (10) engine location.

(2)

Loosen coupling nut (9) that secures steam tube (10) to steam manifold (8).

d.

Loosen coupling nut (11) that secures steam tube (10) to fuel nozzle (1). Remove steam tube.

e.

Place removed steam tube (10) in plastic bag for storage.

f.

Disconnect liquid tubes (16 and 17) from liquid manifolds (14 and 15) as follows: (1)

Using marking pen, position mark liquid tubes (16 and 17) engine location.

(2)

Loosen coupling nuts (20 and 21) that secures liquid tubes (16 and 17) to liquid manifolds (14 and 15).

g.

Loosen coupling nuts (18 and 19) that secures liquid tubes (16 and 17) to fuel nozzle (1). Remove liquid tubes.

h.

Place removed liquid tubes (16 and 17) in plastic bag for storage.

i.

Disconnect fuel tube (5, 6, or 7) from fuel manifold (4) as follows: (1)

Using marking pen, position mark fuel tube (5, 6, or 7) engine location.

(2)

Loosen coupling nuts (12) that secure fuel tube (5, 6, or 7) to fuel manifold (4). 3




Figure 1. Fuel Nozzle and Liquid Fuel, Gas Fuel, and Water Manifolds (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Fuel Nozzle and Liquid Fuel, Gas Fuel, and Water Manifolds (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



j.


k.

Place removed fuel tube (5, 6, or 7) in plastic bag for storage.

l.


Remove safety wire that secures three bolts (3) to fuel nozzle (1).

(2)




(4)


(5)


m. Using masking tape, cover opening in CRF.

7.

n.

Repeat steps c. through m. for all fuel nozzles to be removed.

o.




b.


c.







d.

e.

f.

g.

h.

(2)


(3)

Using three bolts (3), secure fuel nozzle (1) to CRF fuel nozzle mounting boss. Finger-tighten three bolts.

Install liquid tubes (16 and 17) onto liquid manifolds (14 and 15) as follows: (1)

Using grease, lubricate liquid manifolds (14 and 15) nipples where liquid tubes (16 and 17) will connect.

(2)

Align liquid tubes (16 and 17) coupling nuts (20 and 21) with liquid manifolds (14 and 15) nipples. Tighten coupling nuts hand-tight.

Install liquid tubes (16 and 17) onto fuel nozzle (1) as follows: (1)

Using grease, lubricate fuel nozzle (1) nipples where liquid tubes (16 and 17) will connect.

(2)

Align liquid tubes (16 and 17) coupling nuts (18 and 19) with fuel nozzle (1) nipples. Tighten coupling nuts hand-tight.

Install steam tube (10) onto steam manifold (8) as follows: (1)

Using grease, lubricate steam manifold (8) nipple where steam tube (10) will connect.

(2)

Align steam tube (10) coupling nut (9) with steam manifold (8) nipple. Tighten coupling nuts hand-tight.

Install steam tube (10) onto fuel nozzle (1) as follows: (1)

Using grease, lubricate fuel nozzle (1) nipple where steam tube (10) will connect.

(2)

Align steam tube (10) coupling nut (11) with fuel nozzle (1) nipple. Tighten coupling nuts hand-tight.

Install fuel tube (5, 6, or 7) onto fuel manifold (4) as follows: (1)

Using grease, lubricate fuel manifold (4) nipple where fuel tube (5, 6, or 7) will connect.

(2)

Align fuel tube (5, 6, or 7) coupling nut (12) with fuel manifold (4) nipple. Tighten coupling nuts hand-tight.


GEK 105054 Volume II SWP 101 08 i.



Using grease, lubricate fuel nozzle (1) nipples where fuel tube (5, 6, or 7) onto will connect.

(2)

Align fuel tube (5, 6, or 7) coupling nut (13) with fuel nozzle (1) nipple. Tighten coupling nuts hand-tight.

j.

Repeat steps a. through i. for all fuel nozzles to be installed.

k.

Final tighten bolts securing fuel nozzles to CRF to 55-70 lb in. (6.3-7.9 N⋅m) of torque. Safety-wire bolts. CAUTION DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT.

l.



(2)


(3)


DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT. m. Triple tighten coupling nut (19) as follows: (1)


(2)


(3)





DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT. n.



(2)


(3)

Check coupling nut by reapplying 75-91 lb ft (101.7-123.4 N⋅m) of torque at each joint sequentially in a clockwise direction ALF. CAUTION

DO NOT OVER-TORQUE COUPLING NUTS OR DAMAGE TO FUEL FEEDER TUBES MAY RESULT. o.

p.



(2)


(3)







TECHNICAL PROCEDURES LIQUID FUEL MANIFOLD REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Manifold Installation. ......................................................................................................... Manifold Removal................................................................................................................

6 3




Introduction. This work package provides instructions for the removal and installation of the liquid fuel manifold.

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Configuration Fuel System Inspection Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 101 00 WP 415 00 GEK 105055


Part No.

Nylon Sling

Local Purchase



Isopropyl Alcohol Masking Tape

Fed Spec TT-I-735 Local Purchase


IPB Figure No./Item

Metal Seal

37-39




Manifold Removal. a.

Comply with all instructions contained in WP 002 00.

b.

Remove fuel tubes per applicable SWP. Consult WP 101 00 for fuel system configuration. NOTE Packager’s connections include two fuel inlet pressure taps, fuel manifold drain, and fuel supply inlet.

c.

Remove packager’s connections to fuel manifold (figure 1) per packager’s manual. NOTE There are two fuel manifold sections located on the engine. Removal procedure is same for both.

d.

Remove seven bolts (4) and self-locking nuts (5) that secure fuel supply tube (1) to fuel manifold section (7 or 8). Remove and discard metal seal (6). CAUTION TEMPORARILY SUPPORT FUEL MANIFOLD SECTIONS WHEN REMOVING SHOULDER BOLTS THAT CONNECT TWO SECTIONS. FUEL MANIFOLD SECTIONS ARE SECURED TO ENGINE USING HINGED BRACKETS TO EASE ALIGNMENT DURING REASSEMBLY. FUEL MANIFOLD SECTIONS MAY DROP ONTO ENGINE CAUSING DAMAGE IF NOT PROPERLY SUPPORTED DURING REMOVAL.

e.

Remove two shoulder bolts (9) that secure two fuel manifold halves together.

f.

Remove fuel manifold section (7 or 8) from engine as follows: (1)

Remove bolt (11), washer (12), and self-locking nut (13) that secure loop clamp (14) onto hinged bracket (15).

(2)

Remove loop clamp (14) and half bushings (10) from fuel manifold section (7 or 8).

(3)

Repeat substeps (1) and (2) for three remaining hinged bracket locations.




Figure 1. Fuel Manifold Removal (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Fuel Manifold Removal (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY.

7.

g.

Using nylon sling and hoist, remove fuel manifold section from engine.

h.

Using masking tape, cover all manifold openings.

i.

If desired, repeat steps d. through h. for other fuel manifold section.

Manifold Installation. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. a.

Remove masking tape from manifold openings. Using isopropyl alcohol, clean all openings.

b.

Using nylon sling and hoist, align fuel manifold section (7 or 8, figure 1) with engine.

c.

Install fuel manifold section (7 or 8) onto engine as follows: (1)

Install loop clamp (14) and half bushings (10) onto fuel manifold section (7 or 8).

(2)

Using bolt (11), washer (12), and self-locking nut (13), secure loop clamp (14) onto hinged bracket (15). Tighten bolt hand-tight.

(3)

Repeat substeps (1) and (2) for three remaining hinged bracket locations.

d.

If required, install other fuel manifold section (7 or 8) per steps a. through c.

e.

Lift and adjust fuel manifold sections (7 and 8) on engine so boltholes in ends of manifolds are aligned.

f.

Using two shoulder bolts (9), secure two fuel manifold sections (7 and 8) together. Tighten bolts to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

g.

Install metal seal (6) onto inlet port of fuel manifold sections.




h.

Using seven bolts (4) and self-locking nuts (5), secure fuel supply tube (1) to fuel manifold section (7 or 8). Tighten bolts hand-tight.

i.

If required, repeat step h. for other fuel manifold section (7 or 8).

j.

Tighten all bolts (11) to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

k.

Tighten all bolts (4) to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

l.

Install fuel tubes per applicable SWP. Consult WP 101 00 for fuel system configuration.

m. Perform leak check to fuel system after installation per Chapter 7-3.7.





TECHNICAL PROCEDURES NATURAL GAS FUEL MANIFOLD REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.



6 3




Introduction.

This work package provides instructions for the removal and installation of the natural gas fuel manifold. This manifold is also used as a steam manifold in liquid fuel systems that utilize steam injection for nitrogen oxide (NOx) suppression. 2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Configuration Fuel System Inspection Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 101 00 WP 415 00 GEK 105055


Part No.

Nylon Sling

Local Purchase






IPB Figure No./Item

Spiral Seal Gasket

TBP






b.

Remove gas fuel tubes per applicable SWP. Consult WP 101 00 for fuel system configuration. NOTE Packager’s connections include one pressure tap and inlet port.

c.

Remove packager’s connections to fuel manifold per packager’s manual. NOTE When used as steam manifold, entire manifold is axially rotated 180 degrees. Manifold inlet port is located at approximately 11:00 o’clock. Removal of steam manifold from engine is same as natural gas manifold.

d.

Remove manifold section (1, figure 1) from engine as follows: CAUTION USE A NYLON SLING TO SUPPORT TOP FUEL MANIFOLD SECTION AND A NYLON SLING TO SUPPORT LOWER MANIFOLD SECTION DURING REMOVAL OF SUPPORT BRACKETS, OR DA MAGE TO ENGINE MAY OCCUR. (1)

Remove two bolts (12) that secure retaining strap (13) to support bracket (14). Repeat for two other support bracket locations.

(2)

Remove two bolts (7), washers (8), and self-locking nuts (9) that secure cushioned loop clamp (11) to hinge bracket (10). Repeat for two other locations.

(3)

Remove four bolts (3), and self-locking nuts (4) that secure two manifold sections (1 and 2) together. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (4)

Using nylon sling and hoist, lift and remove manifold section (1). Remove and discard spiral seal gasket (5).




Figure 1. Manifold Removal (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Manifold Removal (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. e.

f. 7.

Using nylon sling and hoist, remove manifold section (2) from engine as follows: (1)

Remove two bolts (12) that secure retaining strap (13) to support bracket (14).

(2)

Remove two bolts (7), washers (8), and self-locking nuts (9) that secure cushioned loop clamp (11) to hinge bracket (10). Repeat for two other locations.

(3)

Using nylon sling and hoist, lift and remove manifold section (2).

Cover all manifold openings with masking tape.

Manifold Installation. a.

Using nylon sling and hoist, align manifold section (2) with engine and packager’s mounts as follows: (1)

Using two bolts (12), loosely secure retaining strap (13) to support bracket (14).

(2)

Using two bolts (7), washers (8), and self-locking nuts (9), loosely secure cushioned loop clamp (11) to hinge bracket (10). Repeat for two other locations. WARNING

ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. b.

Remove masking tape from manifold openings. Using isopropyl alcohol, clean all openings.

c.

Install manifold section (1) onto loosely installed manifold section (2) as follows: (1)

Install new spiral seal gasket (5) onto manifold section (2) flange.

(2)

Using nylon sling and hoist, align manifold section (1) with engine and manifold section (2) flange.




Using four bolts (3), with spiral seal gasket (5), and self-locking nuts (4), loosely secure manifold sections (1 and 2) together.

d.

Install gas fuel tubes per applicable SWP. Consult WP 101 00 for fuel system configuration.

e.

Install fuel manifold supports and final tighten manifold hardware as follows: (1)

For manifold section (2), final tighten two bolts (12) securing retaining strap (13) to support bracket (14) to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

(2)

For manifold section (2), final tighten two bolts (7) with washers (8), and self-locking nuts (9) securing cushioned loop clamp (11) to hinge bracket (10) to 33-37 lb in. (3.8-4.1 N⋅m) of torque. Repeat for two other locations.

(3)

For manifold section (1), final tighten two bolts (12) securing retaining strap (13) to support bracket (14) to 55-70 lb in. (6.3-7.9 N⋅m) of torque. Repeat for two other support brackets.

(4)

For manifold section (1), final tighten two bolts (7), with washers (8), and self-locking nuts (9), securing restraining strap (11) to hinge bracket (10). to 33-37 lb in. (3.8-4.1 N⋅m) of torque. Repeat for two other hinge brackets.

(5)

Final tighten four bolts (3) with spiral seal gasket (5) and self-locking nuts (4), securing manifold sections (1 and 2) together to 100-130 lb in. (11.3-14.6 N⋅m) of torque.

f.

Connect manifold section (2) to packager’s connections per packager’s manual.

g.






TECHNICAL PROCEDURES DUAL LIQUID MANIFOLD REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 9 ................... 0 10 Blank............ 0 Alphabetical Index Page


7 3




Introduction. This work package provides instructions for the removal and installation of the liquid manifolds associated with dual fuel systems. These manifolds can be configured to provide two sources of liquid fuel, or liquid fuel and water for systems utilizing water injection for nitrogen oxide (NOx) suppression.

2.

Reference Material. Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Configuration Fuel System Inspection

3.

4.

5.

GEK 105054 WP 002 00 WP 101 00 WP 415 00


Part No.

Nylon Sling

Local Purchase











b.

Remove liquid fuel tubes per applicable SWP. Consult WP 101 00 for fuel system configuration.

c.

If required, remove natural gas fuel manifold per applicable SWP. Consult WP 101 00 for fuel system configuration. NOTE

•

Packager’s connections include two inlet pressure taps, two inlet temperature sensors, and two inlet supplies.

•

Inlet supplies can be configured as either two liquid fuel supplies or liquid fuel supply and water supply.

d.

Remove packager’s connections to fuel manifold per packager’s manual.

e.

Remove primary and secondary inlet supply tubes (6 and 7, figure 1) as follows:

f.

(1)

Loosen B-nuts that secure primary inlet supply tube (6) to supply tubes (15 and 17).

(2)

Loosen B-nuts that secure secondary inlet supply tube (7) to supply tubes (16 and 18).

(3)

Remove two bolts (2) that secure loop clamps (3) to bracket (1).

(4)


(5)

Remove bolt (8) that secures loop clamp (9) to engine.

(6)

Remove bolt (10), flat washer (11), and self-locking nut (12) that secures loop clamp (13) and primary inlet supply tube (6) to bracket (14). Remove primary inlet supply tube. If desired, remove all loop clamps from inlet supply tube.

(7)

Remove bolt (10), flat washer (11), and self-locking nut (12) that secures loop clamp (13) and secondary inlet supply tube (7) to bracket (14). Remove secondary inlet supply tube. If desired, remove all loop clamps from inlet supply tube.

Remove four manifold sections (22, 23, 24, and 25) as follows: (1)

Remove two bolts (19), flat washers (20), and self-locking nuts (21) that secure manifold section (22) to manifold section (25).

(2)

Remove two bolts (19), flat washers (20), and self-locking nuts (21) that secure manifold section (23) to manifold section (24).




Figure 1. Dual Fuel System Liquid Manifolds Replacement (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Dual Fuel System Liquid Manifolds Replacement (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Use nylon sling to support manifold sections (22 and 23) during removal. (3)

Remove four bolts (30), flat washers (31), and self-locking nuts (32) that secure loop clamps (33) and manifold sections (22 and 23) to hinge brackets (34 and 35). WARNING


Using nylon sling and hoist, lift and remove manifold sections (22 and 23) from engine. NOTE

Use nylon sling to support manifold sections (24 and 25) during removal.

g.

h.

i.

(5)

Remove four bolts (30), flat washers (31), and self-locking nuts (32) that secure loop clamps (33) and manifold sections (24 and 25) to hinge brackets (34).

(6)

Using nylon sling and hoist, lift and remove manifold sections (24 and 25) from engine.

If desired, separate manifold sections (22 and 23) as follows: (1)

Remove bolts (26) and self-locking nuts (27) that secure loop clamp (28) to loop clamp (29).

(2)

Remove four loop clamps (28 and 29) from manifold sections (22 and 23).

(3)

Remove four loop clamps (33) from manifold section (22).

If desired, separate manifold sections (24 and 25) as follows: (1)

Remove bolts (26) and self-locking nuts (27) that secure loop clamp (28) to loop clamp (29).

(2)

Remove loop clamps (28 and 29) from manifold sections (24 and 25).

(3)

Remove four loop clamps (33) from manifold section (25).






Remove masking tape from all manifold openings. Using isopropyl alcohol, clean all openings.

b.

If required, prepare manifold sections (22 and 23, figure 1) for installation as follows:

c.

d.

(1)

If removed, install four loop clamps (28) onto manifold section (22).

(2)


(3)


(4)

Using four bolts (26) and self-locking nuts (27), secure loop clamps (28) to loop clamps (29). Tighten bolts finger-tight.

If required, prepare manifold sections (24 and 25) for installation as follows: (1)


(2)


(3)


(4)

Using four bolts (26) and self-locking nuts (27), secure loop clamps (28) to loop clamps (29). Tighten bolts finger-tight.

Install manifold sections (22, 23, 24, and 25) onto engine as follows: WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (1)

Using nylon sling and hoist, lift and align manifold sections (24 and 25) on engine.

(2)

Using four bolts (30), flat washers (31), and self-locking nuts (32), secure loop clamps (33) to hinge brackets (34). Tighten bolts finger-tight.

(3)

Using nylon sling and hoist, lift and align manifold sections (22 and 23) on engine.

(4)

Using four bolts (30), flat washers (31), and self-locking nuts (32), secure loop clamps (33) to hinge brackets (34 and 35). Tighten bolts finger-tight. 7



e.


(5)

Align manifold sections on engine. Using two bolts (19), flat washers (20), and self-locking nuts (21), secure manifold section (22) to manifold section (25). Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

(6)

Using two bolts (19), flat washers (20), and self-locking nuts (21), secure manifold section (23) to manifold section (24). Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

Install primary and secondary inlet supply tubes (6 and 7) as follows: (1)

If removed, install loop clamps (3 and 13) onto inlet supply tubes (6 and 7).

(2)

If removed, install loop clamp (9) onto primary inlet supply tube (6).

(3)

Using two bolts (10), flat washers (11), and self-locking nuts (12), secure loop clamps (13) to bracket (14). Tighten bolts finger-tight

(4)

Using two bolts (2), secure loop clamps (3) to bracket (1). Tighten bolt finger-tight.

(5)

Using two bolts (4), secure loop clamps (5) to bracket (1). Tighten bolt finger-tight.

(6)

Using bolt (8), secure loop clamp (9) to engine. Tighten bolt hand-tight.

(7)

Using B-nuts, connect primary inlet supply tube (6) to supply tubes (15 and 17). Tighten B-nuts as follows: (a) Tighten B-nuts to 650-770 lb in. (73.4-87.0 N⋅m) of torque. (b) Loosen until B-nut is free running and retighten to 650-770 lb in. (73.4-87.0 N⋅m) of torque at each joint. (c) Check B-nuts by reapplying 650-770 lb in. (73.4-87.0 N⋅m) of torque at each joint.

(8)

Using B-nuts, connect secondary inlet supply tube (7) to supply tubes (16 and 18). Tighten B-nuts as follows: (a) Tighten B-nuts to 650-770 lb in. (73.4-87.0 N⋅m) of torque. (b) Loosen until B-nut is free running and retighten to 650-770 lb in. (73.4-87.0 N⋅m) of torque at each joint. (c) Check B-nuts by reapplying 650-770 lb in. (73.4-87.0 N⋅m) of torque at each joint.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE Packager’s connections include two inlet pressure taps, two inlet temperature sensors, and two inlet supplies. f.

Install packager’s connections to fuel manifold per packager’s manual.

g.

Install liquid fuel tubes per applicable SWP. Consult WP 101 00 for fuel system configuration.

h.

If removed, install natural gas fuel manifold per applicable SWP. Consult WP 101 00 for fuel system configuration.

i.

Final tighten manifold hardware as follows:

j.

(1)

Tighten bolts (2 and 4) to 33-37 lb in. (3.8-4.1 NÞm) of torque.

(2)

Tighten bolts (10) to 33-37 lb in. (3.8-4.1 NÞm) of torque.

(3)

Tighten bolts (26 and 30) to 33-37 lb in. (3.8-4.1 NÞm) of torque.






TECHNICAL PROCEDURES STEAM MANIFOLD REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.



8 3




Introduction. This work package provides instructions for the removal and installation of the steam manifold used for nitrogen oxide (NOx) suppression with various fuel systems.

2.

Reference Material. Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Configuration Fuel System Inspection Illustrated Parts Breakdown

3.

4.

5.

GEK 105054 WP 002 00 WP 101 00 WP 415 00 GEK 105055


Part No.

Nylon Sling Wrench Set - Steam Tube

Local Purchase 1C8204






IPB Figure No./Item

Gasket Gasket

42-114 42-118






b.

Disconnect packager steam supply connections per packager’s manual.

c.

Remove insulation blanket (2, figure 2) as follows:

d.

(1)

Cut safety wire that secures insulation blanket (2) sections together.

(2)

Carefully remove insulation blanket (2) from steam manifold sections (8 and 16).

Remove steam supply tubes (1) as follows. Refer to figure 1. Consult WP 101 00 for fuel system configuration. (1)

Position the counter torque wrench, 1C8204P02, on the fuel nozzle.

(2)

Fit the coupling nut wrench, 1C8204P03, over the steam supply tube and slide into position on the nut located in the counter bored hole of the “B” nut wrench.

(3)

Apply force as required to tighten or loosen the coupling nut reacting an equal force in the opposite direction through the counter torque wrench.

e.

If required, remove associated fuel manifolds per applicable SWP. Consult WP 101 00 for fuel system configuration.

f.

Remove steam manifold section (16) as follows: (1)

Remove any packager connections to steam manifold section (16) per packager’s manual. CAUTION

USE NYLON SLING TO SUPPORT STEAM MANIFOLD SECTION DURING REMOVAL. (2)

Remove bolt (13), flat washer (14), and self-locking nut (15) that secures steam manifold section (16) to threaded rod-end (12).

(3)

Remove two bolts (22), flat washers (23), and self-locking nuts (24) that secure steam manifold section (16) to threaded rod-ends (17) and link mounts (19).

(4)

Remove eight bolts (3), flat washers (4), and self-locking nuts (5) that secure steam manifold section (16) to steam manifold section (8).




Figure 1. Steam Tube Wrench, 1C8204 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. Steam Manifold Replacement (Sheet 1 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. Steam Manifold Replacement (Sheet 2 of 2) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY.

g.

(5)

Using nylon sling and hoist, lift and remove steam manifold section (16). Remove and discard gasket (6).

(6)

Using masking tape, cover all steam manifold section (16) openings.

Remove steam manifold section (8) as follows: CAUTION USE NYLON SLING TO SUPPORT STEAM MANIFOLD SECTION DURING REMOVAL. (1)

Remove two bolts (22), flat washers (23), and self-locking nuts (24) that secure steam manifold section (8) to threaded rod-ends (17) and link mounts (19).

(2)

Remove any packager’s connections to steam manifold section (8) per packager’s manual. WARNING


h.

(3)

Using nylon sling and hoist, lift and remove steam manifold section (8). Remove and discard gasket (7).

(4)

Using masking tape, cover all steam manifold section (8) openings.

If required, remove link mount (19) as follows: NOTE Do not cut safety wire that secures plain nuts (18 and 20) to threaded rod-ends (17 and 21). (1)

Remove bolt (22), flat washer (23), and self-locking nut (24) that secures link mount (19) to bracket (25).

(2)

Remove link mount (19) from engine.

(3)

Repeat substeps (1) and (2) for three remaining link mounts (19).





Remove masking tape from all steam manifold section (8, figure 2) openings. Using isopropyl alcohol, clean all openings. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. NOTE A hydraulic jack or overhead hoist should be used to support steam manifold sections during installation.

b.

Position steam manifold sections (8 and 16) around engine at approximately forward high pressure compressor (HPC) stator casing aft flange position. NOTE Leave approximately 0.020 inch (0.51 mm) gap between manifold flange and gasket (6) when tightening bolts (3). This will allow for alignment of steam manifold mounting hardware.

c.

Install gasket (6) between steam manifold sections (8 and 16) using eight bolts (3), flat washers (4), and self-locking nuts (5). Tighten bolts finger-tight. NOTE If removed, threaded rod-end (12) and rod-end (10) bolthole centerto-center length shall be approximately 3.0 inches (76.2 mm).

d.

Using bolt (13), flat washer (14), and self-locking nut (15), secure threaded rodend (12) to steam manifold section (16). Tighten bolt (13) to 190-230 lb in. (21.5-25.9 N⋅m) of torque.

e.

Tighten steam manifold flange bolts (3) to 100-130 lb in. (11.3-14.6 N⋅m) of torque.

f.

If required, install associated fuel manifolds per applicable SWP. Consult WP 101 00 for fuel system configuration.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines g.

Install steam supply tubes (1) per applicable SWP. Consult WP 101 00 for fuel system configuration.

h.

Install gasket (7) onto packager’s steam supply flange. Ensure interface flange of steam manifold is aligned with packager’s connection.

i.

If removed, install link mount (19) as follows: NOTE If safety wire is missing from plain nuts (18 and 20) and threaded rodends (17 and 21), ensure link mount length is 13.25 inches (33.6 cm), measured from bolthole center-to-center, prior to installing link mounts. (1)

Using bolt (22), flat washer (23), and self-locking nut (24), secure link mount (19) to bracket (25). Tighten bolt to 190-230 lb in. (21.5-25.9 N⋅m) of torque.

(2)

Repeat step (1) for remaining link mounts (19).

j.

Using bolts (22), flat washers (23), and self-locking nuts (24), secure two link mounts (19) to steam manifold sections (8 and 16). Adjust length of links as necessary to install bolts (22). Tighten bolts to 190-230 lb in. (21.5-25.9 N⋅m) of torque.

k.

Remove hydraulic jack or overhead hoist.

l.

Connect steam manifold sections (8 and 16) to packager’s connections per packager’s manual.

m. Inspect steam manifold per WP 415 00. n.

Install insulation blanket (2) onto steam manifold as follows: (1)

Place insulation blanket (2) sections onto steam manifold.

(2)

Using safety wire installed onto capstans, secure insulation blanket (2) on steam manifold. No gaping, pulling, or tearing of insulation blankets shall be allowed.





TECHNICAL PROCEDURES WATER MANIFOLD REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.



6 3




Introduction. This work package provides instructions for the removal and installation of the water manifold used for nitrogen oxide (NOx) suppression with natural gas fuel systems.

2.

Reference Material. Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Configuration Fuel System Inspection

3.

4.

5.

GEK 105054 WP 002 00 WP 101 00 WP 415 00


Part No.

Nylon Sling

Local Purchase











b.

Remove water tubes per applicable SWP. Consult WP 101 00 for fuel system configuration.

c.

If required, remove natural gas fuel manifold per applicable SWP. Consult WP 101 00 for fuel system configuration. NOTE Packager’s connections include inlet pressure tap, inlet temperature sensor, and inlet supply.

d.

Remove packager’s connections to fuel manifold per packager’s manual.

e.

Remove inlet supply tube (4, figure 1) as follows:

f.

(1)

Loosen B-nuts that secure inlet supply tube (4) to supply tubes (12 and 13).

(2)


(3)

Remove bolt (6) that secures loop clamp (5) to engine.

(4)

Remove bolt (7), flat washer (8), and self-locking nut (9) that secures loop clamp (10) and inlet supply tube (4) to bracket (11). Remove inlet supply tube.

(5)

If desired, remove all loop clamps from inlet supply tube.

Remove two manifold sections (14 and 18) as follows: (1)

Remove two bolts (15), flat washers (16), and self-locking nuts (17) that secure manifold section (14) to manifold section (18). NOTE

Use nylon sling to support manifold section (14) during removal. (2)

Remove six bolts (20), flat washers (21), and self-locking nuts (22) that secure loop clamps (23) and manifold section (14) to hinge brackets (19 and 24).




Figure 1. Water Manifold Replacement (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Water Manifold Replacement (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.




Using nylon sling and hoist, lift and remove manifold section (14) from engine. NOTE

Use nylon sling to support manifold section (18) during removal.

7.

(4)

Remove five bolts (20), flat washers (21), and self-locking nuts (22) that secure loop clamps (23) and manifold section (18) to hinge brackets (19 and 24).

(5)

Using nylon sling and hoist, lift and remove manifold section (18) from engine.

g.

If desired, remove loop clamps from manifold sections (14 and 18).

h.


Manifold Installation. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. a.

Remove masking tape from all manifold openings. Using isopropyl alcohol, clean all openings.

b.

If required, prepare manifold sections (14 and 18, figure 1) for installation as follows: (1)

If removed, install six loop clamps (23) onto manifold section (14).

(2)





Install manifold sections (14 and 18) onto engine as follows: WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY.

d.

e.

(1)

Using nylon sling and hoist, lift and align manifold section (14) on engine.

(2)

Using six bolts (20), flat washers (21), and self-locking nuts (22), secure loop clamps (23) to hinge brackets (19 and 24). Tighten bolts finger-tight.

(3)

Using nylon sling and hoist, lift and align manifold section (18) on engine.

(4)

Using five bolts (20), flat washers (21), and self-locking nuts (22), secure loop clamps (23) to hinge brackets (19 and 24). Tighten bolts finger-tight.

(5)

Align manifold sections on engine. Using two bolts (15), flat washers (16), and self-locking nuts (17), secure manifold section (14) to manifold section (18). Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

Install inlet supply tube (4) as follows: (1)

If removed, install loop clamps (2, 5, and 10) onto inlet supply tube (4).

(2)

Using bolt (7), flat washer (8), and self-locking nut (9), secure loop clamp (10) to bracket (11). Tighten bolts finger-tight

(4)

Using two bolts (3), secure loop clamps (2) to bracket (1). Tighten bolts finger-tight.

(5)

Using bolt (6), secure loop clamp (5) to engine. Tighten bolt hand-tight.

(7)

Using B-nuts, connect inlet supply tube (4) to supply tubes (12 and 13). Tighten B-nuts to 650-770 lb in. (73.5-86.9 N⋅m) of torque.

Install packager’s connections to water manifold per packager’s manual.




f.

Install water tubes per applicable SWP. Consult WP 101 00 for fuel system configuration.

g.

Final tighten manifold hardware as follows:

h.

(1)

Tighten bolts (3) to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(2)

Tighten bolt (7) to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(3)


(4)

Tighten bolts (20) to 33-37 lb in. (3.8-4.1 N⋅m) of torque





WORK PACKAGE

TECHNICAL PROCEDURES FIVE ELEMENT LUBE AND SCAVENGE PUMP REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 10 ................. 0


Page

Lube and Scavenge Pump Installation. ............................................................................. Lube and Scavenge Pump Removal. ..................................................................................

6 3


GEK 105054 Volume II WP 102 00 1.


Introduction. This work package contains instructions for removal and installation of five element lube and scavenge pump used on LM2500+ Models GK and GV gas generators and LM2500+ Model PV gas turbine.

2.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Lube and Scavenge Pump Screen, Electronic Chip Detector, and Magnetic Detector Plug Inspection Illustrated Parts Breakdown

GEK 105054 Chapter 7 GEK 105054 WP 002 00

3.


4.


Specification

Lubricating Oil



WP 400 00 GEK 105055



Preformed Packing Preformed Packing Round Gasket Seal Gasket Seal Gasket Seal Gasket

56-41 59-48/56-32 59-8 59-10 59-39 59-11




Lube and Scavenge Pump Removal. NOTE For LM 2500+ Models GV and PV, consult GEK 105052 or packager’s manual as necessary. a.

Comply with all instructions contained in WP 002 00. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

b.

Tag and disconnect three electrical leads from scavenge line RTD sensors (24, figure 1, sheet 1).

c.

If applicable, tag and disconnect electronic chip detector leads from lube and scavenge pump screens. WARNING

•


•


d.

Tag and disconnect scavenge oil hoses connected to accessory gearbox scavenge tube (1), accessory gearbox scavenge tube (2), B-sump scavenge tube (18), and C-sump scavenge tube (19). Drain residual oil into approved waste container.

e.

Tag and disconnect transfer gearbox scavenge tube (17) from lube and scavenge pump (26) by removing three bolts (15).

f.

Tag and disconnect hoses/tubes connected to lube oil supply inlet tube (10), lube oil discharge tube (8), and scavenge discharge tube (6). Drain residual oil into approved waste container.

g.

Disconnect spline lube tube (28, sheet 2) from tube nipple (20, sheet 1) on bottom of lube and scavenge pump (26). Disconnect drain tube (27) from tube nipple (14) on bottom of lube and scavenge pump. Drain residual oil into approved waste container.




Figure 1. Five Element Lube and Scavenge Pump Replacement (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Five Element Lube and Scavenge Pump Replacement (Sheet 2 of 2) h.

Disconnect hydraulic pump return hose (30) from lube oil discharge tube (8).

i.

Loosen clamps on spline lube tube (28) and drain tube (27), to allow slight movement. CAUTION ENSURE LUBE AND SCAVENGE PUMP IS SUPPORTED DURING REMOVAL OF V-BAND CLAMP, TO REDUCE RISK OF DAMAGE TO SPLINE DRIVE.

j.

Loosen V-band clamp (23) and carefully remove lube and scavenge pump (26) from gearbox. Discard gasket (22).

k.

Remove flange tubes as follows: (1)

Remove self-locking nut (35), flat washer (34), and bolt (33) that secures clamp (5) to bracket (4).

(2)




l.


(3)


(4)

Remove 15 bolts (15) that secure scavenge discharge tube (6), lube oil discharge tube (8), lube oil supply inlet tube (10), B-sump scavenge tube (18), and C-sump scavenge tube (19) to lube and scavenge pump (26). Remove tubes.

(5)

Remove two bolts (15), and one bolt (31), and two self-locking nuts (32) that secure accessory gearbox scavenge tube (1) and bracket (4) to lube and scavenge pump (26). Remove tube and bracket.

(6)

Remove two bolts (15) and one bolt (31), and two self-locking nuts (32) that secure accessory gearbox scavenge tube (2) and bracket (9) to lube and scavenge pump (26). Remove tube and bracket.

Remove three flange gaskets (3, 12, and 16) from top of lube and scavenge pump (26). Inspect gaskets for serviceability and replace, if required.

m. Remove tube nipples (14 and 20) from bottom of lube and scavenge pump (26). Remove and discard preformed packings (13 and 21). n. 7.

Cover or cap all openings, to prevent entry of foreign material.

Lube and Scavenge Pump Installation. a.

Inspect lube and scavenge pump (26) screens per WP 400 00. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Using lubricating oil, lubricate gaskets (3, 12, and 16) and preformed packings (13 and 21).

c.

Uncover or uncap all openings closed in paragraph 6., step l. Ensure caps (25) are installed.

d.

Install gasket (3) onto lube and scavenge pump (26).

e.

Install accessory gearbox scavenge tubes (1 and 2) onto lube and scavenge pump (26). Install bolt (31) into forward bolthole of each tube flange and fingertighten.




f.

Install bracket (4) to aft boltholes in flange of accessory gearbox scavenge tube (1), if not installed. Secure with two bolts (15) and self-locking nuts (32) and finger-tighten.

g.

Install bracket (9) to aft boltholes in flange of accessory gearbox scavenge tube (2), if not installed. Secure with two bolts (15) and self-locking nuts (32) and finger-tighten.

h.


i.

Install C-sump scavenge tube (19) and B-sump scavenge tube (18). Secure each tube with three bolts (15) installed from bottom and tighten bolts finger-tight.

j.


k.

Install scavenge discharge tube (6), lube oil discharge tube (8), and lube oil supply inlet tube (10). Secure each with three bolts (15) installed from bottom and finger-tightened.

l.

If not previously done, install clamp (5) onto scavenge discharge tube (6), loop aft. Using bolt (33), self-locking nut (35), and flat washer (34), attach clamp to bracket (4). Tighten nut finger-tight.

m. If not previously done, install clamp (7) onto lube oil discharge tube (8), loop up. Using bolt (33), self-locking nut (35), and flat washer (34), attach clamp to bracket (9). Tighten nut finger-tight. n.

If not previously done, install clamp (11) onto lube oil supply inlet tube (10), loop up. Using bolt (33), self-locking nut (35), and flat washer (34), attach clamp to bracket (9). Tighten nut finger-tight.

o.

Install preformed packing (21) onto tube nipple (20). Install tube nipple into lube and scavenge pump (26). Tighten tube nipple to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

p.


q.

Spread V-band clamp (23) and slip over gearbox mounting flange. Position V-band clamp with bolt at bottom and nut to left (viewed aft looking forward).

r.

Install lube and scavenge pump gasket (22) onto lube and scavenge pump flange. Hang gasket over locating dowel pin at 12:00 o'clock position on lube and scavenge pump flange.




LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. s.

Lubricate lube and scavenge pump drive splines with lubricating oil. Align lube and scavenge pump drive splines, and place lube and scavenge pump into mounted position. Ensure locating dowel pin enters hole in gearbox flange.

t.

Position V-band clamp (23) over lube and scavenge pump (26) and gearbox flanges. Tighten as follows: (1)

Tighten socket-head screw to approximately 65 lb in. (7.3 N·m) of torque.

(2)

Inspect and ensure V-band clamp (23) is seated over both flanges equally.

(3)

Using plastic or non-metallic mallet, tap V-band clamp (23) around circumference to distribute band tension.

(4)

Tighten socket-head screw to 70-90 lb in. (7.9-10.1 N·m) final torque. Continue to lightly tap V-band clamp (23) to prevent unequal loading.

(5)

After full value torque is applied, tap circumference of V-band clamp (23) again. Reapply torque to ensure V-band clamp is properly tightened.

(6)

Safety-wire V-band clamp (23).

u.

Connect transfer gearbox scavenge tube (17) to lube and scavenge pump (26) using three bolts (15). Tighten bolts to 55-70 lb in. (6.2-7.9 N⋅m) of torque.

v.

Install drain tube (27) onto tube nipple (14). Tighten tube to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

w.

Install spline lube tube (28, sheet 2) onto tube nipple (20, sheet 1). Tighten tube to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

x.

Connect hydraulic pump return hose (30) to lube oil discharge tube (8). Tighten return hose to 450-550 lb in. (50.9-62.1 N⋅m) of torque. CAUTION WHEN INSTALLING AND CONNECTING FLEXIBLE HOSES, ENSURE HOSES ARE ISOLATED FROM SOURCES OF CHAFING, OR DAMAGE TO FLEXIBLE HOSES SHALL OCCUR.

y.

Align lube and scavenge pump tubes and flexible hoses. Attach hoses to tube and hand-tighten couplings. Remove and discard tags.

z.

Tighten all clamp nuts to 33-37 lb in. (3.8-4.1 N⋅m) of torque.




aa. Tighten flange bolts/nuts that secure tubes to lube and scavenge pump (26) to 55-70 lb in. (6.2-7.9 N⋅m) of torque. ab. Tighten connections between flexible hoses and lube and scavenge pump tubes to torque values per table 1. ac. Open lube oil supply between lube oil storage and conditioning assembly and gas generator per packager’s manual. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. ad. Loosen lube inlet screen (29) two turns and hold until steady stream of lubricating oil flows between threads. Do not completely unscrew screen. ae. After oil flows continuously, tighten oil screen. Tighten screen to 55-70 lb in. (6.2-7.9 N⋅m) of torque and safety-wire. Table 1. Lube and Scavenge Pump Tube and Hose Torque Values Torque to

Tube/Hose (figure 1)

lb ft

N⋅m

B-sump scavenge tube (18)

112-128

151.9-173.5

C-sump scavenge tube (19)

112-128

151.9-173.5

Lube oil supply inlet tube (10)

158-183

214.2-248.1

Lube oil discharge tube (8)

112-128

151.9-173.5

Scavenge discharge tube (6)

75-87

101.7-118.0

Accessory gearbox scavenge tube (1)

54-64

73.2-86.8


54-64

73.2-86.8

WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. af. Ensure electrical leads are correctly located. Attach electrical leads to RTD sensors (24), hand-tighten, and safety-wire. Remove tags.




ag. If applicable, connect electronic chip detector leads onto appropriate screen per packager’s manual. Remove tags. ah. Motor gas generator for 2 minutes per GEK 105054, Chapter 7, to purge lube system of air and check for leaks. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. ai.

Check lube oil level after coast down. Using lubricating oil, refill lube oil storage tank, if necessary.





TECHNICAL PROCEDURES SIX ELEMENT LUBE AND SCAVENGE PUMP REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 10 ................. 0


Page

Lube and Scavenge Pump Installation. ............................................................................. Lube and Scavenge Pump Removal. ..................................................................................

6 3




Introduction. This work package contains instructions for removal and installation of the six element lube and scavenge pump used on LM2500+ Model PK gas turbine.

2.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Lube and Scavenge Pump Screen, Electronic Chip Detector, and Magnetic Plug Inspection Illustrated Parts Breakdown


3.


4.



Lubricating Oil



WP 400 00 GEK 105055


IPB Figure No./Item

Gasket Gasket Preformed Packing Preformed Packing Round Gasket Seal Gasket Seal Gasket Seal Gasket

59-10 59-39 59-48/56-32 56-41 59-8 59-53 59-53 59-52




Lube and Scavenge Pump Removal. a.


b.

Tag and disconnect four electrical leads from four scavenge line RTD sensors (24, figure 1, sheet 1).

c.

Tag and disconnect electronic chip detector leads from screens. WARNING

•


•


d.

Tag and disconnect scavenge oil hoses connected to D-sump scavenge tube (1), accessory gearbox scavenge tube (2), B-sump scavenge tube (18), and C-sump scavenge tube (19). Drain residual oil into approved waste container.

e.

Tag and disconnect hoses from lube oil supply inlet tube (10), lube oil discharge tube (8), and tube (31) from scavenge discharge tube (6). Drain residual oil into approved waste container.

f.

Disconnect spline lube tube (34, sheet 2) from tube nipple (20, sheet 1) on bottom of lube and scavenge pump (32). Disconnect drain tube (33) from tube nipple (14) on bottom of lube and scavenge pump. Drain residual oil into approved waste container.

g.

Remove air/oil separator scavenge tube (26) as follows: (1)

Remove eight bolts (39) from flanges of air/oil separator scavenge tube (26).

(2)

Remove clamp (27) from bracket that holds air/oil separator scavenge tube (26) on accessory gearbox by removing one bolt (43) and one self-locking nut (44).

(3)

Remove clamp (45) from air/oil separator scavenge tube (26) by removing one bolt (46) and one self-locking nut (47).




Figure 1. Six Element Lube and Scavenge Pump Replacement (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Six Element Lube and Scavenge Pump Replacement (Sheet 2 of 2)

(4)

Remove air/oil separator scavenge tube (26) and gaskets (28 and 29). Discard gaskets.

h.

Remove four bolts (39) from air/oil separator scavenge discharge tube (31). Remove and discard gasket (30).

i.

Loosen clamps on drain tube (33) and scavenge discharge tube (6) to allow slight movement. CAUTION ENSURE LUBE AND SCAVENGE PUMP (32) IS SUPPORTED DURING REMOVAL OF V-BAND CLAMP (23) TO REDUCE RISK OF DAMAGE TO SPLINE DRIVE.

j.

Loosen and remove V-band clamp (23). Carefully remove lube and scavenge pump (32) from gearbox. Remove and discard gasket (22).

k.

Remove four bolts (39) and disconnect air/oil separator scavenge discharge tube (31) from lube and scavenge pump (32). Discard gasket (30).


GEK 105054 Volume II SWP 102 01 l.


Disconnect air/oil separator scavenge discharge tube (31) from scavenge discharge tube (6). Remove air/oil separator scavenge discharge tube.

m. Remove flange tubes as follows:

7.

(1)

Remove self-locking nut (42), flat washer (40), and bolt (41) that secure clamp (5) to bracket (4).

(2)


(3)


(4)

Remove 18 bolts (15) that secure scavenge discharge tube (6), lube oil discharge tube (8), lube oil supply inlet tube (10), TGB scavenge tube (17), Bsump scavenge tube (18), and C-sump scavenge tube (19) to lube and scavenge pump (32). Remove tubes.

(5)

Remove one bolt (15), two bolts (37), and self-locking nuts (38) that secure D-sump scavenge tube (1) and bracket (4) to lube and scavenge pump (32). Remove tube and bracket.

(6)

Remove one bolt (15), two bolts (37), and self-locking nuts (38) that secure accessory gearbox scavenge tube (2) and bracket (9) to lube and scavenge pump (32). Remove tube and bracket.

n.

Remove three gaskets (3, 12, and 16) from top of lube and scavenge pump (32). Inspect gaskets and replace, if required.

o.

Remove tube nipples (14 and 20) from bottom of lube and scavenge pump (32). Remove and discard preformed packings (13 and 21).

p.

Cover or cap all openings of lube and scavenge pump (32), to prevent entry of foreign material.

Lube and Scavenge Pump Installation. a.

Inspect lube and scavenge pump screens per WP 400 00. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Using lubricating oil, lubricate gaskets (3, 12, 16, 28, 29, and 30) and preformed packings.




c.

Uncover or uncap all openings closed in paragraph 6., step p. Ensure caps (25) are installed.

d.


e.

Install D-sump scavenge tube (1) and accessory gearbox scavenge tube (2). Install bolts (15) into forward bolthole of tube flanges. Tighten bolts fingertight.

f.

Install bracket (4) to aft boltholes in flange of D-sump scavenge tube (1). Secure bracket and D-sump scavenge tube with two bolts (37) and self-locking nuts (38). Tighten bolts finger-tight.

g.

Install bracket (9) to aft boltholes in flange of accessory gearbox scavenge tube (2). Secure bracket and accessory gearbox scavenge tube with two bolts (37) and self-locking nuts (38). Tighten bolts finger-tight.

h.


i.

Install C-sump scavenge tube (19), B-sump scavenge tube (18), and TGB scavenge tube (17). Secure each tube with three bolts (15). Install bolts from bottom and tighten bolts finger-tight.

j.

Place gasket (12) onto lube and scavenge pump (32).

k.

Install scavenge discharge tube (6), lube oil discharge tube (8), and lube oil supply inlet tube (10). Secure each with three bolts (15). Install bolts from bottom and tighten bolts finger-tight.

l.

If not previously done, install clamp (5) onto scavenge discharge tube (6), loop aft. Using bolt (41), self-locking nut (42), and flat washer (40), attach clamp to bracket (4). Tighten nut finger-tight.

m. If not previously done, install clamp (7) onto lube oil discharge tube (8), loop up. Using bolt (41), self-locking nut (42), and flat washer (40), attach clamp to bracket (9). Tighten nut finger-tight. n.

If not previously done, install clamp (11) onto lube oil supply inlet tube (10), loop down. Using bolt (41), self-locking nut (42), and flat washer (40), attach clamp to bracket (9). Tighten nut finger-tight.

o.

Install air/oil separator scavenge discharge tube (31) as follows: (1)

Install gasket (30) onto air/oil separator scavenge discharge port of lube and scavenge pump (32).

(2)

Using four bolts (39), attach air/oil separator scavenge discharge tube (31) to lube and scavenge pump (32). Tighten bolts finger-tight.

(3)

Attach air/oil separator scavenge discharge tube (31) onto nipple on scavenge discharge tube (6). 7




p.


q.

Install preformed packing (13) onto tube nipple(14). Install tube nipple into lube and scavenge pump (32). Tighten tube nipple to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

r.

Spread V-band clamp (23) and slip over gearbox mounting flange. Position V-band clamp with bolt at bottom and nut to left (viewed aft looking forward).

s.

Install lube and scavenge pump gasket (22) onto lube and scavenge pump (32) flange. Hang gasket over locating dowel pin at 12:00 o'clock position on lube and scavenge pump flange. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

t.

Lubricate lube and scavenge pump (32) drive splines with lubricating oil. Align lube and scavenge pump drive splines and place lube and scavenge pump into mounted position. Ensure locating dowel pin enters hole in gearbox flange.

u.

Position V-band clamp (23) over lube and scavenge pump (32) and gearbox flanges. Tighten as follows: (1)

Tighten socket-head screw to approximately 65 lb in. (7.3 N⋅m) of torque.

(2)

Inspect and ensure V-band clamp (23) is seated over both flanges equally.

(3)

Using plastic or non-metallic mallet, tap V-band clamp (23) around circumference, to distribute band tension.

(4)

Tighten socket-head screw to 70-90 lb in. (7.9-10.1 N⋅m) final torque. Continue to lightly tap V-band clamp (23) to prevent unequal loading.

(5)

After full value torque is applied, tap circumference of V-band clamp (23) again. Reapply torque, to ensure V-band clamp is properly tightened.

(6)

Safety-wire V-band clamp (23).

v.

Install drain tube (33) onto tube nipple (14). Tighten tube to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

w.

Install spline lube tube (34, sheet 2) onto tube nipple (20, sheet 1). Tighten tube to 135-155 lb in. (15.3-17.5 N⋅m) of torque.




x.

Install new gaskets (28 and 29) onto ends of air/oil separator scavenge tube (26). Using four bolts (39) at each flange, attach scavenge tube onto lube and scavenge pump (32) and air/oil separator. Tighten bolts to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

y.

Using bolt (43) and self-locking nut (44), attach clamp (27) to accessory gearbox bracket. Tighten nut finger-tight.

z.

Using bolt (46) and self-locking nut (47), attach clamp (45) to accessory gearbox bracket. Tighten nut finger-tight. CAUTION WHEN INSTALLING AND CONNECTING FLEXIBLE HOSES, ENSURE HOSES ARE ISOLATED FROM SOURCES OF CHAFING, OR DAMAGE TO FLEXIBLE HOSES SHALL OCCUR.

aa. Align lube and scavenge pump (32) tubes and flexible hoses. Attach hoses to tube and hand-tighten couplings. Remove and discard tags. ab. Tighten all clamp nuts to 33-37 lb in. (3.8-4.1 N⋅m) of torque. ac. Tighten flange tube bolts/nuts as follows: (1)

Tighten air/oil separator scavenge tube (26) and air/oil separator scavenge discharge tube (31). Tighten bolts to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(2)

Tighten remainder of tubes to lube and scavenge pump (32). Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

ad. Tighten connections between flexible hoses and lube and scavenge pump (32) tubes to torque values per table 1. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. ae. Open lubricating oil supply to lube and scavenge pump per packager’s manual. af. Loosen lube inlet screen (35) two turns and hold until steady stream of oil flows between threads. Do not completely unscrew screen. ag. After oil flows continuously, tighten lube inlet screen (35). Tighten screen to 55-70 lb in. (6.3-7.9 N⋅m) of torque and safety-wire.




Table 1. Lube and Scavenge Pump Tube and Hose Torque Values Torque to

Tube/Hose (figure 1)

lb ft

N⋅m

B-sump scavenge tube (18)

112-128

152-174

C-sump scavenge tube (19)

112-128

152-174

D-sump scavenge tube (1)

54-64

73-87

Lube oil supply inlet tube (10)

158-183

214-248

Lube oil discharge tube (8)

112-128

152-174

Scavenge discharge tube (6)

133-150

180-203


54-64

73-87

Air/oil separator scavenge discharge tube (31)

54-64

73-87

Hydraulic pump return hose (36)

38-46

52-62

WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. ah. Attach electrical leads to RTD sensors (24), hand-tighten, and safety-wire. Remove tags. ai.

Connect electronic chip detector leads onto appropriate screen per packager’s manual. Remove tags.

aj.

Motor gas turbine for 2 minutes per GEK 105054, Chapter 7, to purge lube system of air. Check for leaks. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

ak. Check lube oil level after coast down. Using lubricating oil, refill lube oil storage tank, if necessary.




WORK PACKAGE

TECHNICAL PROCEDURES IGNITER PLUG AND IGNITION LEAD REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

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1 - 7 ................... 0 8 Blank.............. 0 Alphabetical Index Page

Subject Igniter Plug Installation. .................................................................................................... Igniter Plug Removal. ......................................................................................................... Ignition Lead Installation................................................................................................... Ignition Lead Removal. .......................................................................................................

5 3 7 5


GEK 105054 Volume II WP 103 00 1.


Introduction. This work package contains instructions for removal and installation of igniter plug(s), igniter port plug, and ignition leads.

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Ignition Exciter Replacement Ignition System Functional Check

GEK 105054 WP 002 00 WP 104 00 WP 409 00


Part No.

Gage, Depth

1C6096G01


Specification

Safety Cable Safety Wire Thread Lubricant

736L680G01 R297P04 (Alt) GE Spec A50TF201 or MIL-T-5544

Expendable Material. None Required.




Igniter Plug Removal. a.

Comply with all instructions contained in WP 002 00. CAUTION IF COMBUSTOR CHAMBER REMOVAL IS TO BE PERFORMED, ENSURE BOTH IGNITER PORTS ARE UNOBSTRUCTED, OR DAMAGE TO COMBUSTOR CHAMBER MAY OCCUR. NOTE Igniter plug is located at 4:00 o’clock position on compressor rear frame (CRF). An optional second igniter plug may be installed at the 5:00 o’clock position. If igniter plug is not installed, port plug shall be installed.

b.

Remove igniter plug at 4:00 o’clock position as follows: WARNING IGNITION SYSTEM SHALL BE INOPERATIVE FOR AT LEAST 2 MINUTES BEFORE DISCONNECTING IGNITION LEADS. IGNITION SYSTEM COULD BE CHARGED WITH LETHAL HIGH VOLTAGE. CAUTION

(1)

•

IGNITION LEAD COUPLING NUT RETAINS SPARK IGNITER IN ADAPTER. DO NOT LET IGNITER DROP FROM ADAPTER AFTER LEAD IS REMOVED, OR DAMAGE TO IGNITER MAY OCCUR.

•

IGNITER PLUG MAY BE RETAINED WITH IGNITION LEAD DURING REMOVAL OF IGNITION LEAD.

Remove safety wire and carefully remove coupling nut (5, figure 1) of ignition lead (6) from adapter (2). CAUTION

IF SAME IGNITER PLUG IS TO BE REINSTALLED, SECURE SHIMS TO IGNITER PLUG USING TAPE TO ENSURE PROPER FIT AT INSTALLATION. NOTE There are metal shims on igniter plug. Quantity may vary from zero to eight. (2)

Remove igniter plug (3) from adapter (2).




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



If second igniter plug is installed at 5:00 o’clock position, remove per step b. If port plug is installed, remove per step d.

d.

Remove port plug if installed, from igniter port at 5:00 o’clock position on CRF as follows:

e.

7.

(1)

Remove safety wire from port plug.

(2)

Remove port plug from adapter.

If required, remove adapter (2) and metal seal ring (1) from CRF (10) as follows: (1)

Remove two bolts (8) and washers (7) that secure adapter (2) to CRF (10).

(2)

Remove adapter (2) and metal seal ring (1) from CRF (10).

Ignition Lead Removal. NOTE There may be two ignition leads and ignition exciters installed. Removal procedure is same for both. a.

If igniter plug (3, figure 1) was retained with ignition lead (6), remove igniter plug.

b.

Remove ignition lead(s) as follows:

c. 8.

(1)

Remove bolt and nut that secure loop clamp of igniter plug at 4:00 o’clock position to air manifold.

(2)

Remove loop clamp from ignition lead.

(3)

If installed, remove clamps that secure ignition lead of igniter plug at 5:00 o’clock position per packager’s manual.

(4)

Remove any off-engine clamps per packager’s manual.

Disconnect ignition lead(s) from ignition exciter per WP 104 00.

Igniter Plug Installation. a.

Install igniter plug (3, figure 1) at 4:00 o’clock position as follows: (1)

If removed, install adapter (2) and metal seal ring (1) as follows: (a) Lubricate bolt (8) threads and washer (7) faces with thread lubricant. (b) Install metal seal ring (1) onto adapter (2).



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (c) Using two bolts (8) and washers (7), secure adapter (2) and metal seal ring (1) to CRF (10). Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. NOTE

•

If same igniter plug is being installed, disregard step (2). If different igniter is being installed, immersion depth shall be established per step (2).

•

Shims are only provided with new igniter plug.

(2)

Determine immersion depth as follows: (a) Using depth gage, 1C6096, measure and record dimension E from outer surface of adapter (2) to bottom surface of combustor (9) ferrule. (b) Measure igniter plug (3) dimension D. (c) Determine number of shims (4) required as follows: 1

Subtract dimension E from dimension D. Dim D

- Dim E

=

NOTE Maximum of eight shims can be added to igniter plug. 2 (3)

Add shims until dimension E - dimension D + dimension C equals 0.030-0.070 inch (0.77-1.77 mm).

Install igniter plug (3) into adapter (2) as follows: (a) Lubricate coupling nut (5) with thread lubricant. (b) If same igniter plug (3) is to be installed, remove tape used to secure shims (4) to igniter plug. (c) Insert igniter plug (3) with shims (4) into adapter (2). (d) Install ignition lead (6) with attached coupling nut (5) onto adapter (2). Tighten coupling nut to 23-27 lb ft (31.2-36.6 N⋅m) of torque and safety-wire.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION ENSURE EITHER IGNITION PLUG OR PORT PLUG IS INSTALLED IN 10:00 O’CLOCK POSITION PORT, OR DAMAGE TO ENGINE SHALL OCCUR.

9.

b.

If second igniter plug is desired, install at 10:00 o’clock position per step a. If port plug is desired, install per step c.

c.

Install port plug at 5:00 o’clock position as follows: (1)

Determine immersion depth per step a.(2).

(2)

Thread port plug into adapter. Tighten port plug to 23-27 lb ft (31.2-36.6 N⋅m) of torque and safety-wire.

Ignition Lead Installation. NOTE

•

Ignition lead shall be installed onto igniter plug per paragraph 8. Ignition lead coupling nut is required to secure igniter plug in CRF.

•

There may be two ignition leads and ignition exciters installed. Installation procedure is same for both.

a.

Install ignition lead(s) and coupling nut(s) per paragraph 8.

b.

Attach ignition lead(s) to ignition exciter per WP 104 00.

c.

If required, secure igniter lead(s) as follows:

d.

(1)

Using bolt, nut, and loop clamp, secure lead of igniter plug located at 4:00 o’clock position to air manifold. Tighten bolt and nut to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

(2)

If optional igniter plug is installed at 5:00 o’clock position, secure lead per packager’s manual.

(3)

Secure off-engine clamps per packager’s manual.

Perform functional check of ignition system per WP 409 00.




WORK PACKAGE

TECHNICAL PROCEDURES IGNITION EXCITER REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Ignition Exciter Installation. .............................................................................................. Ignition Exciter Removal. ...................................................................................................

3 3


GEK 105054 Volume II WP 104 00 1.


Introduction. This work package contains instructions for removal and installation of the ignition exciter. One ignition exciter is required for each igniter plug installed.

2.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Ignition System Functional Check

GEK 105054 WP 002 00 WP 409 00

3.


4.


5.

Nomenclature

Specification

Safety Cable Safety Wire

736L680G01 R297P04 (Alt)





Ignition Exciter Removal. a.

Comply with all instructions contained in WP 002 00. NOTE One ignition exciter is required for each igniter plug installed.

b.

Secure power to ignition exciter per packager’s manual.

c.

Disconnect or loosen clamps, as required, to allow disconnection of electrical cables. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

d.

Disconnect electrical power lead (2, figure 1) from ignition exciter per packager’s manual. WARNING IGNITION SYSTEM SHALL BE INOPERATIVE FOR AT LEAST 2 MINUTES BEFORE DISCONNECTING IGNITION LEADS. IGNITION SYSTEM COULD BE CHARGED WITH LETHAL HIGH VOLTAGE.

7.

e.

Disconnect igniter plug lead (1) from ignition exciter (3).

f.

Remove fasteners that secure ignition exciter (3) per packager’s manual. Remove ignition exciter.

Ignition Exciter Installation. a.

Install ignition exciter (3, figure 1) and secure with fasteners per packager’s manual.

b.

Connect igniter plug lead (1) to ignition exciter connection. Tighten connection to 130-150 lb in. (14.6-16.9 N⋅m) of torque and safety-wire. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

c.

Connect electrical power lead (2) to ignition exciter (3) per packager’s manual.




Figure 1. Ignition Exciter Removal/Installation d.

Connect and secure all clamps removed or loosened in paragraph 6. per packager’s manual.

e.

Perform ignition system functional check per WP 409 00.




WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR SPEED SENSOR REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Gas Generator Speed Sensor Installation.......................................................................... Gas Generator Speed Sensor Removal...............................................................................

6 3


GEK 105054 Volume II WP 105 00 1.


Introduction. This work package contains instructions for removal and installation of gas generator speed sensor.

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Hydraulic Pump Replacement Variable Stator Vane Servovalve Replacement Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 120 00 WP 121 00 GEK 105055


Part No.

Gage, Feeler

Local Purchase


Specification

Isopropyl Alcohol Safety Cable Safety Wire Silicone Rubber Adhesive (RTV-106) Red

Fed Spec TT-I-735 736L680G01 R297P04(Alt) GE Spec A15F6B6



Gasket Self-locking Strap

8-64 6-50




Gas Generator Speed Sensor Removal. a.

Comply with all instructions contained in WP 002 00. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. NOTE There are two identical gas generator speed sensors located on accessory gearbox. Removal procedure is same for both.

b.

Remove speed sensor(s) (figure 1) from accessory gearbox as follows: (1)

Disconnect electrical lead (1, figure 2) from speed sensor (2) per packager’s manual.

(2)

Remove safety wire and loosen jamnut (5) on speed sensor (2).

(3)

Remove speed sensor (2) from accessory gearbox (3).

(4)

Remove jamnut (5) from speed sensor (2).

(5)

Remove self-locking strap (8) and instruction plate (9) from speed sensor. If the same speed sensor will be used again retain instruction plate on speed sensor. WARNING

ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. CAUTION USE CARE TO ENSURE OLD SILICONE RUBBER ADHESIVE DOES NOT FALL INTO ACCESSORY GEARBOX, OR GEARS MAY BECOME DAMAGED. c.

Using alcohol, remove old silicone rubber adhesive from accessory gearbox (3).




Figure 1. Gas Generator Speed Sensors Location 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. Gas Generator Speed Sensor Replacement 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 105 00 7.


Gas Generator Speed Sensor Installation. NOTE If desired, variable stator vane servovalve and hydraulic pump may be removed from accessory gearbox as an assembly. a.

Remove variable stator vane (VSV) servovalve from hydraulic pump per WP 121 00.

b.

Remove hydraulic pump from accessory gearbox per WP 120 00.

c.

Remove cover plate (7) and gasket (6) from access opening on accessory gearbox (3). Retain cover plate and attaching bolts. Inspect gasket for serviceability and replace, if required.

d.

Install jamnut (5) onto speed sensor (2).

e.

Install speed sensor (2) into accessory gearbox (3) as follows: (1)

Thread speed sensor (2) into accessory gearbox (3) to meet required gap of 0.010-0.015 inch (0.26-0.38 mm) between speed sensor tip and tooth crown of spur gear (4).

(2)

Using feeler gage through accessory gearbox access opening, check for required gap. WARNING

VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELL-VENTILATED AREA.

f.

(3)

Apply thin bead of silicone rubber adhesive (approximately 0.06 inch [1.5 mm] diameter), around speed sensor (2) at accessory gearbox (3). Remove excess silicone rubber adhesive from speed sensor threads and accessory gearbox.

(4)

Hold speed sensor (2) and tighten jamnut (5) against accessory gearbox (3). Tighten jamnut while silicone rubber adhesive is still wet. Tighten jamnut to 90-110 lb in. (10.2-12.4 N⋅m) of torque.

(5)

Using feeler gage, recheck clearance between speed sensor tip and tooth crown of spur gear (4) to ensure that it is within limits. Enter clearance setting in engine logbook.

Install gasket (6) and cover plate (7) onto accessory gearbox (3) access opening. Tighten bolts to 33-37 lb in. (3.8-4.1 N⋅m) of torque.




Safety-wire jamnuts (5) of both speed sensors (2) together.

h.

If required, install instruction plate (9) with self-locking strap (8) onto speed sensor (2). WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

i.

Connect electrical lead (1) to speed sensor (2) per packager’s manual. NOTE If desired, VSV servovalve and hydraulic pump may be installed onto accessory gearbox as an assembly.

j.

Install VSV servovalve onto hydraulic pump per WP 120 00.

k.

Install hydraulic pump onto accessory gearbox per WP 121 00.




WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE SPEED TRANSDUCER ELECTRICAL CABLE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Power Turbine Speed Transducer Electrical Cable Installation. ..................................... Power Turbine Speed Transducer Electrical Cable Removal. ..........................................

6 3


GEK 105054 Volume II WP 106 00 1.


Introduction. This work package contains instructions for removal and installation of LM2500+ Model PK power turbine speed transducer electrical cables. For LM2500+ Model PV power turbine speed transducer electrical cables removal and installation, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.

Reference Material. Number

Title For LM2500+ Model PK power turbine: Operation and Maintenance Manual, Volume II General Maintenance Practices Power Turbine Dual Output Speed Transducer Replacement For LM2500+ Model PV power turbine: Operation and Maintenance Manual Illustrated Parts Breakdown 3.


4.


5.

GEK 105054 WP 002 00 SWP 107 01 GEK 105052 GEK 105053

Nomenclature

Specification

Safety Cable Safety Wire

736L680G01 R297P04 (Alt)





Power Turbine Speed Transducer Electrical Cable Removal. a.

Comply with all instructions contained in WP 002 00. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. NOTE Electrical lead for power turbine dual outlet speed transducer, PN L44630, is an integral part of the transducer and cannot be removed. Removal and installation of electrical lead shall be accomplished during removal and installation of speed transducer per SWP 107 01.

b.

Disconnect packager supplied leads from power turbine speed transducer electrical cable connectors on panel bracket (5, figure 1) per packager’s manual.

c.

Remove right power turbine speed transducer electrical cable (2) from power turbine as follows: (1)

Remove bolt (7) and self-locking nut (6) that secure loop clamp (9) to panel bracket (5). Remove loop clamp from panel.

(2)

Remove bolt (7) and self-locking nut (6) that secure loop clamp (9) to bracket (8). Remove loop clamp from bracket.

(3)

Remove bolt (14) and nut (15) that secure loop clamp (13) to bracket (12).

(4)

Remove safety wire that secures right power turbine speed transducer electrical cable (2) connector to right power turbine speed transducer (1).

(5)

Disconnect right power turbine speed transducer electrical cable (2) connector from right power turbine speed transducer (1).

(6)

Remove jamnut from right power turbine speed transducer electrical cable (2) connector at connector panel bracket (5).

(7)

Remove right power turbine speed transducer electrical cable (2) from power turbine. If different power turbine speed transducer electrical cable is to be installed, remove loop clamps (9) from right power turbine speed transducer electrical cable.




Figure 1. Power Turbine Speed Transducer Electrical Cable Removal/Installation 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Remove left power turbine speed transducer electrical cable (3) from power turbine as follows: NOTE Integral accelerometer lead loop clamps are retained on power turbine using bolts and nuts that secure power turbine speed transducer electrical cables. Temporarily secure integral accelerometer lead out of way, during power turbine speed transducer electrical cable removal. (1)

Remove bolt (7) and self-locking nut (6) that secure loop clamp (9) to panel bracket (5). Using safety wire, temporarily secure loop clamp (10) that retains integral accelerometer lead onto panel bracket.

(2)

Remove bolt (7) and self-locking nut (6) that secure loop clamp (9) to bracket (8). Using safety wire, temporarily secure loop clamp (10) that retains integral accelerometer lead onto bracket.

(3)

Remove bolt (7) and self-locking nut (6) that secure loop clamp (9) to bracket (11).

(4)

Remove three bolts (7) and self-locking nuts (6) that secure loop clamps (9) to brackets (8).

(5)

Remove bolt (14) and nut (15) that secure loop clamp (13) to bracket (12).

(6)

Remove safety wire that secures left power turbine speed transducer electrical cable (3) connector to left power turbine speed transducer (4).

(7)

Disconnect left power turbine speed transducer electrical cable (3) connector from left power turbine speed transducer (4).

(8)

Remove jamnut from left power turbine speed transducer electrical cable (3) connector at panel bracket (5).

(9)

Remove left power turbine speed transducer electrical cable (3) from power turbine. If different power turbine speed transducer electrical cable is to be installed, remove loop clamp (9) from left power turbine speed transducer electrical cable.


GEK 105054 Volume II WP 106 00 7.


Power Turbine Speed Transducer Electrical Cable Installation. a.

Install right power turbine speed transducer electrical cable (2, figure 1) onto power turbine as follows: (1)

Using bolt (7) and self-locking nut (6), secure loop clamp (9) to panel bracket (5). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(2)

Using bolt (7) and self-locking nut (6), secure loop clamp (9) to bracket (8). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(3)

Using bolt (14) and nut (15), secure loop clamp (13) to bracket (12). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque. CAUTION

ENSURE SEAL RING IS LOCATED IN ELECTRICAL CONNECTOR PRIOR TO INSTALLING RIGHT POWER TURBINE SPEED TRANSDUCER ELECTRICAL CABLE ONTO RIGHT POWER TURBINE SPEED TRANSDUCER.

b.

(4)

Connect right power turbine speed transducer electrical cable (2) connector to right power turbine speed transducer (1). Use soft-jawed pliers to tighten knurled ring of electrical connector beyond finger-tight, 20 degrees maximum and safety-wire.

(5)

Install right power turbine speed transducer electrical cable (2) connector onto panel bracket (5). Install jamnut onto connector. Tighten jamnut to 25-30 lb in. (2.9-3.3 N⋅m) of torque.

Install left power turbine speed transducer electrical cable (3) onto power turbine as follows: NOTE Integral accelerometer lead loop clamps are retained on power turbine using bolts and nuts that secure power turbine speed transducer electrical cables. (1)

Using bolt (7) and self-locking nut (6), secure loop clamps (9 and 10) to panel bracket (5). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(2)

Using bolt (7) and self-locking nut (6), secure loop clamps (9 and 10) to bracket (8). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(3)

Using bolt (7) and self-locking nut (6), secure loop clamp (9) to bracket (11). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.




Using three bolts (7) and self-locking nuts (6), secure loop clamps (9) to brackets (8). Tighten bolts to 33-37 lb in. (3.8-4.1 N⋅m) of torque. CAUTION

ENSURE SEAL RING IS LOCATED IN ELECTRICAL CONNECTOR PRIOR TO INSTALLING LEFT POWER TURBINE SPEED TRANSDUCER ELECTRICAL CABLE ONTO LEFT POWER TURBINE SPEED TRANSDUCER. (5)

Connect left power turbine speed transducer electrical cable (3) connector to left power turbine speed transducer (4). Use soft-jawed pliers to tighten knurled ring of electrical connector beyond finger-tight, 20 degrees maximum and safety-wire.

(6)

Install left power turbine speed transducer electrical cable (3) connector through connector panel bracket (5). Install jamnut onto connector. Tighten jamnut to 25-30 lb in. (2.9-3.3 N⋅m) of torque. WARNING

ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. c.

Connect packager supplied leads onto left and right power turbine speed transducer electrical cable connectors at panel bracket (5) per packager’s manual.

d.

Perform an operational check of power turbine speed indication system per Chapter 7-3.7.




WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE SPEED TRANSDUCER REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 12 ................. 0


Page

Power Turbine Speed Transducer Installation.................................................................. Power Turbine Speed Transducer Removal....................................................................... Power Turbine Speed Transducer Tip Clearance Measurement......................................

9 3 5


GEK 105054 Volume II WP 107 00 1.


Introduction. This work package contains instructions for removal and installation of LM2500+ Model PK power turbine speed transducer. For LM2500+ Model PV power turbine speed transducer removal and installation, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title For LM2500+ Model PK power turbine: Operation and Maintenance Manual, Volume II General Maintenance Practices Power Turbine Speed Pickup Lead Replacement Illustrated Parts Breakdown For LM2500+ Model PV power turbine: Operation and Maintenance Manual Illustrated Parts Breakdown 3.

4.

GEK 105052 GEK 105053


Part No.

Gage, Clearance - Overspeed Transducer

1C6345G01



Lubricating Oil

MIL-L-23699 or MIL-L-7808 Action Marker or Sharpie T.E.C. GE Spec A50TF201

Marking Pen Thread Lubricant 5.

GEK 105054 WP 002 00 WP 106 00 GEK 105055


IPB Figure No./Item

Preformed Packing Shim Pack

72-7 72-8




Power Turbine Speed Transducer Removal. a.


b.

Disconnect electrical lead from transducer per WP 106 00. CAUTION TRANSDUCER SPRING IS RETAINED UNDER COMPRESSION BY SPRING RETAINER. RETAINER BOLTS MUST BE LOOSENED IN SMALL, EQUAL AMOUNTS, TO PREVENT BINDING. NOTE There are two speed transducers located in turbine rear frame. One in strut No. 3 and one in strut No. 7. This procedure applies to both. Clearance gage, 1C6345, is required to remove, adjust, and install transducers. Items contained in clearance gage are shown in figures 1 and 2.

c.

If same transducer will be installed into same strut using same shim pack, mark location of all parts using marking pen.

d.

Loosen nuts (5, figure 1) on each of three spring retainer bolts (6), two turns at a time, until bolts are removed. Remove angle bracket (9), spring retainer (8), and spring (10).

e.

Slide flanged plug (2) over end of transducer (7). Screw knurled nut (3) onto transducer, and against flanged plug. Finger-tighten knurled nut.

f.

Install three jackscrews (1) into tapped holes of flanged plug (2).

g.

Tighten jackscrews (1) in small, equal amounts, to disengage transducer (7) from inside turbine frame strut (11).

h.

Remove knurled nut (3) and flanged plug (2) from transducer (7).




Figure 1. Power Turbine Speed Transducer Removal/Installation



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE Transducer is equipped with a flexible section that facilitates removal in small enclosures. Parts of steps i. through n. may not be necessary. i.

Slide transducer (7) out of turbine frame strut (11) until both sets of wrenching flats (13) are exposed.

j.

Hold inner wrenching flat (13) and unscrew outer support tube (14) from transducer (7).

k.

Carefully slide transducer back into strut until there is at least 12 inches (304.8 mm) of clearance between end of transducer and package wall (if applicable).

l.

Carefully remove outer support tube (14) from transducer (7).

m. Slide transducer (7) out of strut flange (12), to expose flexible section of transducer (19). CAUTION DO NOT EXCEED A 90 DEGREE BEND OF FLEXIBLE SECTION OF TRANSDUCER. USE CARE TO PREVENT DAMAGE TO POLE PIECE AT INNER END OF TRANSDUCER. USE CARE TO PREVENT DAMAGE TO CONNECTOR END OF TRANSDUCER.

7.

n.

Carefully bend flexible section of transducer (19) as required, to maximum of 90 degrees, and remove transducer from strut.

o.

Install outer support tube (14) onto transducer (7) and hand-tighten connection.

p.

Remove and discard preformed packings (18).

Power Turbine Speed Transducer Tip Clearance Measurement. CAUTION IF SHIMS HAVE BEEN DISTURBED OR IF TRANSDUCER IS NEW TO THIS FRAME STRUT, TIP CLEARANCE SHALL BE DETERMINED BEFORE TRANSDUCER IS INSTALLED. DAMAGE TO TRANSDUCER CAN RESULT FROM IMPROPER TIP CLEARANCE. a.

Insert sleeve (1, figure 2), with wrenching flat (12) on outer end, into strut flange (14), and leave wrenching flat exposed. Connect flanged sleeve (2) onto sleeve (1) and hand-tighten until firmly seated.

b.

Slide sleeve (1) and flanged sleeve (2) into frame, until sleeves bottom onto strut inner seating surface. Sleeve flange should be approximately 0.25 inch (6.35 mm) from strut flange (14). 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. Power Turbine Speed Transducer Tip Clearance Measurement 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



c.

Secure sleeve assembly (1 and 2) to strut flange (14) with three bolts (6) and nuts (5). Tighten nuts to 10-15 lb in. (1.2-1.6 N⋅m) of torque.

d.

Pivot shaft assembly (4) at center joint, only as far as necessary, and not more than 90 degrees, and insert end of shaft assembly into sleeve (1) and flanged sleeve (2). Straighten shaft assembly and align setscrew (7) with slot (13) in sleeve. Carefully insert shaft assembly until shaft threads touch flanged sleeve (2) threads.

e.

Screw shaft assembly (4) into flanged sleeve (2) assembly by hand, until tip of shaft assembly touches spur gear teeth. Hand-tighten shaft assembly (4).

f.

Rotate split nut (3) until it contacts flanged sleeve (2). Insert spanner wrench or short, 0.19 inch diameter (4.8 mm) rod into split nut to serve as wrench. Tighten split nut.

g.

Tighten socket capscrew (8) hand-tight, to lock split nut (3) into place. CAUTION DO NOT LOOSEN SPLIT NUT ONCE IT IS TIGHTENED IN PLACE, OR IMPROPER TIP CLEARANCE MAY RESULT. TRANSDUCER TIP MAY BE DAMAGED IF INSERTED TOO FAR INTO FRAME.

h.

Unscrew shaft assembly (4) from sleeve (1) and flanged sleeve (2). Do not loosen split nut (3). Pull shaft assembly outward, pivot 90 degrees at center joint, and remove from sleeve assembly.

i.

Remove bolts (6) and nuts (5) that hold sleeve (1) and flanged sleeve (2) from strut flange (14). Slide sleeve assembly out, to expose wrenching flat (12). Separate flanged sleeve from sleeve and remove both sleeves from frame.

j.

Connect flanged sleeve (2) to sleeve (1) and tighten until firmly seated.

k.

Insert shaft assembly (4) into sleeve (1) and flanged sleeve (2). Screw shaft assembly into sleeve assembly until split nut (3) seats against sleeve flange.

l.

Retract micrometer (10) and insert shaft/sleeve assembly into gage fixture. Secure assembly with three bolts (6) and nuts (5). Tighten nuts to 10-15 lb in. (1.2-1.6 N⋅m) of torque.

m. Extend spindle of micrometer (10) until it touches shaft tip. Record micrometer reading. n.

Retract micrometer (10) spindle and remove bolts (6) and nuts (5). Remove shaft/sleeve assembly from gage fixture.

o.

Lubricate threads of nut (15) with thread lubricant.




Install nut with capscrew wrench holes, towards shim pack. p.

Install new shim pack (16) and serviceable nut (15) onto new transducer (19). Hold shim pack in place and hand-tighten nut. CAUTION ENSURE CAPSCREWS ENTER HOLES IN NUT TO PREVENT DAMAGE TO NUT.

q.

Insert transducer (19) into gage fixture. Tighten capscrews (11). Using crowfoot wrench on transducer end wrenching flat (12), tighten nut to 181-199 lb in. (20.5-22.4 N⋅m) of torque. Loosen capscrews.

r.

Place spring (17) and spring retainer (18) onto transducer (19). Secure spring retainer onto gage fixture with three bolts (6) and nuts (5). Tighten nuts to 10-15 lb in. (1.2-1.6 N⋅m) of torque.

s.

Extend spindle of micrometer (10) until it touches tip of transducer (19). Record micrometer reading.

t.

Determine required shim pack (16) size as follows: (1)

Subtract reading recorded in step m. from reading recorded in step s. and record difference. - M

S (2)

If difference recorded equals 0.032-0.044 inch (0.812-1.117 mm), proceed with installation of transducer.

(3)

If difference is less than 0.032 inch (0.812 mm) or more than 0.044 inch (1.117 mm), determine number of shims to be removed or added onto shim pack (16). Each shim has thickness of 0.001-0.003 inch (0.025-0.076 mm). Example: =

(4) u.

=

0.596 inch (15.14 mm) from step r. 0.536 inch (13.61 mm) from step m. 0.060 inch (1.53 mm)

For above example, peel seven shims (0.003 inch [0.08 mm] each or 0.021 inch [0.53 mm]) total from shim pack (16).

Remove three retaining bolts (6) and nuts (5) slowly and in equal amounts. Remove spring retainer (18) and spring (17).



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines v.

Retract micrometer (10) spindle and carefully remove transducer from gage fixture.

w.

Remove nut (15) and shim pack (16) from transducer (19). Peel shims from shim pack, as determined in step t.

x.

Install corrected shim pack (16) and nut (15) onto transducer (19). Hold shim pack in place and hand-tighten nut.

y.

Repeat steps q. through s.

z.

Subtract reading recorded in step m. from new reading recorded in step y.

aa. If this value equals 0.032-0.044 inch (0.812-1.117 mm), proceed with installation of transducer. If this value is less than 0.032 inch (0.812 mm) or greater than 0.044 inch (1.117 mm), repeat steps t. through z. Do not repeat steps t. through z. more than once, without repeating all of paragraph 7. Example:

0.058 inch (1.473 mm) from step x. -

0.020 inch (0.508 mm) from step m.

=

0.038 inch (0.965 mm)

ab. Remove three retaining bolts (6) and nuts (5) slowly and in equal amounts. Remove spring retainer (18) and spring (17). ac. Retract micrometer (10) spindle and carefully remove transducer from gage fixture. 8.

Power Turbine Speed Transducer Installation. CAUTION IF SHIMS HAVE BEEN DISTURBED OR IF TRANSDUCER IS NEW TO THIS FRAME STRUT, PARAGRAPH 7 SHALL BE ACCOMPLISHED BEFORE INSTALLING TRANSDUCER. DAMAGE TO TRANSDUCER OR INADEQUATE SIGNAL CAN RESULT FROM IMPROPER CLEARANCE. NOTE

a.

•

There are two speed transducers located in turbine rear frame. One in strut No. 3 and one in strut No. 7. This procedure applies to both.

•

Check markings on transducer to reinstall. Install transducers into strut from which removed.

•

Transducer is equipped with a flexible section that facilitates removal in small enclosures. Parts of steps a. through d. may not be necessary.

Hold inner wrenching flat (13, figure 1) and unscrew outer support tube (14) from transducer (7). Do not apply any torque to flexible section of transducer (19). 9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. Speed Transducer - Pickup End 10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. b.

Lubricate two new preformed packings with lubricating oil (figure 3) and install onto tip of speed transducer assembly. CAUTION DO NOT EXCEED 90 DEGREE BEND OF TRANSDUCER. USE CARE TO PREVENT DAMAGE TO POLE PIECE AT INNER END OF TRANSDUCER. USE CARE TO PREVENT DAMAGE TO CONNECTOR END OF TRANSDUCER.

c.

Carefully bend speed transducer assembly (figure 3), as required, but not more than 90 degrees, and insert into turbine rear frame strut. Straighten speed transducer assembly and install until outer support can be slipped over end.

d.

Install outer support tube (14, figure 1) onto transducer and tighten to 200-240 lb in. (22.6-27.1 N⋅m) of torque. Only use provided wrenching flat (13) to tighten outer support tube.

e.

Place flanged plug (2) onto transducer (7).

f.

Insert set plug (4) into transducer connector, so slot in set plug engages index key in connector. Rotate transducer (7) until arrow on set plug is pointing to 12:00 o'clock position.

g.

Remove set plug (4). Do not rotate transducer (7) once indexed.

h.

Carefully push transducer/flanged plug assembly inward. Install bolts (6, figure 2) and nuts (5) to hold flanged plug (2, figure 1) to strut flange (12). Tighten bolts evenly until transducer (7) is seated.

i.

Insert set plug (4) into transducer connector and engage slot of set plug with index key in connector. Check to ensure position of arrow has not changed.

j.

Remove set plug (4) and flanged plug (2) from transducer (7).


GEK 105054 Volume II WP 107 00 k.


Place spring (figure 3) and spring retainer over end of transducer. Position angle bracket onto spring retainer. Install three bolts and nuts to secure bracket and retainer onto strut flange. Draw bolts down alternately in small, equal amounts. Tighten nuts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

l.

Install power turbine speed sensor leads per WP 106 00.

m. Perform an operational check of power turbine speed indication system after maintenance per Chapter 7-3.7.





TECHNICAL PROCEDURES POWER TURBINE DUAL OUTPUT SPEED TRANSDUCER REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 8 ................... 0


Page

Power Turbine Dual Output Speed Transducer Installation. .......................................... Power Turbine Dual Output Speed Transducer Removal. ...............................................

7 3




Introduction. This subordinate work package contains instructions for removal and installation of LM2500+ Model PK power turbine dual output speed transducer. For LM2500+ Model PV power turbine speed transducer removal and installation, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title For LM2500+ Model PK power turbine: Operation and Maintenance Manual, Volume II General Maintenance Practices Illustrated Parts Breakdown For LM2500+ Model PV power turbine: Operation and Maintenance Manual Illustrated Parts Breakdown 3.

4.

5.

GEK 105054 WP 002 00 GEK 105055 GEK 105052 GEK 105053


Part No.

Set, Jackscrew

1C6804G04



Lubricating Oil

MIL-L-23699 or MIL-L-7808


IPB Figure No./Item

Preformed Packing

72-7




Power Turbine Dual Output Speed Transducer Removal. a.

Comply with all instructions contained in WP 002 00. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. NOTE Electrical lead for power turbine dual output speed transducer is an integral part of the transducer and cannot be removed from transducer.

b.

Disconnect transducer electrical connectors per packager’s manual. CAUTION TRANSDUCER SPRING IS RETAINED UNDER COMPRESSION BY SPRING RETAINER. RETAINER BOLTS MUST BE LOOSENED IN SMALL, EQUAL AMOUNTS TO PREVENT BINDING.

c.

Remove nut (15, figure 1), bolt (16), and loop clamp (17) securing electrical lead (13) to angle bracket (3).

d.

Loosen nuts (1) on each of three spring retainer bolts (2), two turns at a time, until bolts are removed. Remove angle bracket (3). NOTE Step e. through h. applies only if spring retainer (5) cannot be removed by hand.

e.

Rotate spring retainer (5) and spacer (14) until threaded holes line up with face of strut flange (7).

f.

Install three jackscrews (0.250-28 UNF) from jackscrew set, 1C6804, into threaded holes in spring retainer (5). NOTE Spring (4) and spring retainer (5) cannot be removed from transducer (6).

g.

Tighten jackscrews in small, equal amounts to disengage spring retainer (5) from strut flange (7).

h.

Remove jackscrews from spring retainer (5).




Figure 1. Power Turbine Dual Output Speed Transducer Removal/Installation (Sheet 1 of 2)




Figure 1. Power Turbine Dual Output Speed Transducer Removal/Installation (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



HANDLE TRANSDUCER CAREFULLY TO PREVENT DAMAGE TO POLE PIECE AT INNER END OF TRANSDUCER. NOTE Transducer is equipped with a flexible section that facilitates removal in small enclosures. Steps i. through l., n., and o. may not be necessary. i.

Slide transducer (6) out of turbine rear frame (TRF) strut (8) until both sets of wrenching flats (9) are exposed.

j.

Hold inner wrenching flat (9) and unscrew outer support tube (10) from transducer (6).

k.

Carefully slide outer support tube (10) into TRF strut (8).

l.

Slide transducer (6) out of strut flange (7), to expose flexible section (11) of transducer (6). CAUTION DO NOT EXCEED A 90 DEGREE BEND OF TRANSDUCER FLEXIBLE SECTION. HANDLE TRANSDUCER WITH CARE TO PREVENT DAMAGE TO POLE PIECE AT INNER END OF TRANSDUCER.

m. Remove speed transducer (6) as follows: (1)

If sufficient space is available, remove speed transducer (6) from TRF strut (8).

(2)

If sufficient space is not available, carefully bend flexible section (11) of transducer (6) as required, to maximum of 90 degrees, and remove transducer from strut.

n.

Remove outer support tube (10) from TRF strut (8).

o.

Install outer support tube (10) onto transducer (6) and hand-tighten connection.

p.

Remove and discard preformed packings (12).

q.

Remove spacer (14) from transducer (6). Retain spacer for reuse.




Power Turbine Dual Output Speed Transducer Installation. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. NOTE

a.

•

If sufficient space to install speed transducer is not available and outer support tube is installed, perform step a. through j.

•

If sufficient space to install speed transducer is available, perform step a., d. and g. through j.

•

Transducer is equipped with a flexible section that facilitates installation in small enclosures. Steps b. through d. may not be necessary.

Lubricate two new preformed packings (12, figure 1) with lubricating oil and install onto speed transducer (6). CAUTION DO NOT APPLY TORQUE TO FLEXIBLE SECTION OF TRANSDUCER. OTHERWISE, DAMAGE MAY RESULT.

b.

Hold inner wrenching flat (9) and unscrew outer support tube (10) from transducer (6). Do not apply any torque to flexible section (11) of transducer (6).

c.

Insert outer support tube (10) into TRF strut (8).

d.

Reinstall spacer (14), previously removed, onto speed transducer (6). CAUTION DO NOT EXCEED 90 DEGREE BEND OF TRANSDUCER FLEXIBLE SECTION (11). HANDLE TRANSDUCER WITH CARE TO PREVENT DAMAGE TO POLE PIECE AT INNER END OF TRANSDUCER. NOTE Make sure FWD marking on speed transducer is facing forward during and after installation.

e.

Carefully bend speed transducer assembly, as required, but not more than 90 degrees, and insert into TRF strut (8). Straighten speed transducer assembly and install until outer support tube (10) can be installed. 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



f.

Install outer support tube (10) onto transducer (6) and tighten to 200-240 lb in. (22.6-27.1 N⋅m) of torque. Only use provided wrenching flats (9) to tighten outer support tube.

g.

Carefully push speed transducer assembly inward. Install spring retainer bolts (2), nuts (1), and angle bracket (3) to hold transducer (6) to strut flange (7). Tighten bolts evenly until transducer is seated. Tighten to 55-70 lb in. (6.2-7.9 N⋅m) of torque.

h.

Secure electrical lead (13) to angle bracket (3) using loop clamp (17), bolt (16), and nut (15). Tighten nut to 33-37 lb in. (3.7-4.2 N⋅m) of torque. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICALLY CAUSES SHOCK, BURNS, AND DEATH.

i.

Connect transducer electrical connectors per packager’s manual.

j.

Perform operational check of power turbine speed indication system after maintenance per Volume I, Chapter 7-3.7.




WORK PACKAGE

TECHNICAL PROCEDURES THERMOCOUPLE PROBE (T5.4) AND HARNESS REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV

LIST OF EFFECTIVE PAGES Total Number of Pages in this WP is 6 Page No.

Change No.

Page No.

Change No.

Page No.

Change No.


Subject Thermocouple Harness Installation................................................................................... Thermocouple Harness Removal. ....................................................................................... Thermocouple Probe Installation. ...................................................................................... Thermocouple Probe Removal. ...........................................................................................

5 5 3 3


GEK 105054 Volume II WP 108 00 1.


Introduction.

This work package contains instructions for removal and installation of thermocouple probes and harnesses. 2.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Thermocouple Probe (T5.4) Inspection

GEK 105054 WP 002 00 WP 419 00

3.


4.


5.

Nomenclature

Specification







Thermocouple Probe Removal. a.

Comply with all instructions contained in WP 002 00. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. NOTE There are eight individual thermocouple probes located on the turbine mid frame. Removal procedure is same for all thermocouple probes.

7.

b.

Loosen retaining nuts (1 and 2, figure 1) that secure right or left thermocouple harness (3 or 4) to thermocouple probe (5). Disconnect thermocouple harness from thermocouple probe.

c.

Remove safety wire and loosen coupling nut (6) that secures thermocouple probe (5) to turbine mid frame (TMF). Remove thermocouple probe.

d.

Repeat steps b. and c. for all applicable thermocouple probes.

Thermocouple Probe Installation. a.

Inspect T5.4 thermocouple probe per WP 419 00. NOTE There are eight individual thermocouple probes located on the TMF. Installation procedure is same for all thermocouple probes.

b.

Lightly coat threads of probe boss on TMF with thread lubricant. CAUTION

c.

•

INSTALL THERMOCOUPLE PROBE CAREFULLY TO PREVENT DAMAGE TO PROBE.

•

ENSURE THERMOCOUPLE PROBE IS INSTALLED WITH THREE TABS ON PROBE FLANGE INSERTED INTO THREE SLOTS IN MOUNTING BOSS. IMPROPER INSTALLATION CAN DAMAGE PROBE AND SHALL RESULT IN ERRONEOUS TEMPERATURE READINGS.

Install thermocouple probe (5, figure 1) into TMF. Align three tabs of thermocouple flange with three slots in mounting boss.




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



8.

d.

Start coupling nut (6) onto boss threads. Tighten coupling nut to 70-80 lb in. (8.0-9.0 N⋅m) of torque and safety-wire.

e.

Install thermocouple harness (3 or 4) onto thermocouple probe (5) per paragraph 9.

Thermocouple Harness Removal. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. NOTE There are two thermocouple harnesses per engine. Removal procedure is same for both.

9.

a.

Disconnect packager supplied cable from harness connector (7, figure 1) per packager’s manual.

b.

Disconnect thermocouple harness (3 or 4) from thermocouple probes (5) per paragraph 6.

c.

Remove jamnut and disconnect harness connector (7) from support bracket (8).

d.

Remove bolts (9) that secure loop clamps (10, 12, or 14) to brackets (11 or 13).

e.

Repeat step d. for remaining brackets (11 or 13) and loop clamps (10, 12, or 14).

f.

Remove thermocouple harness (3 or 4) from engine.

g.

If thermocouple harness (3 or 4) is to be replaced, remove loop clamps (10) from thermocouple harness. Retain bolts (9) and loop clamps (10, 12, or 14), if serviceable.

h.

If required, repeat steps a. through g. to remove other thermocouple harness (3 or 4).

Thermocouple Harness Installation. NOTE There are two thermocouple harnesses per engine. Installation procedure is same for both. a.

Position thermocouple harness (3 or 4, figure 1) around engine.

b.

If required, install loop clamps (10, 12, or 14) onto thermocouple harness (3 or 4). 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



c.

Align loop clamps (10, 12, or 14) on thermocouple harness (3 or 4) with brackets (11 or 13) on TMF aft flange.

d.

Using bolts (9), secure loop clamps (10, 12, or 14) to brackets (11 or 13). Tighten bolts finger-tight.

e.

If installed, remove harness connector (7) jamnut. Install harness connector through support bracket (8).

f.

Tighten harness connector (7) jamnut to 25-30 lb in. (2.9-3.3 N⋅m) of torque.

g.

Remove kinks, slack, and/or excessive tension on thermocouple harness (3 or 4). Tighten bolts (9) to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

h.

Connect thermocouple harness (3 or 4) to thermocouple probe (5) as follows: CAUTION DO NOT OVERTIGHTEN THERMOCOUPLE HARNESS RETAINING NUTS. FAILURE TO COMPLY MAY RESULT IN PART DAMAGE.

i.

(1)

Tighten larger diameter retaining nut (2) to 46-50 lb in. (5.2-5.6 N⋅m) of torque.

(2)

Tighten smaller diameter retaining nut (1) to 18-22 lb in. (2.1-2.4 N⋅m) of torque.

If required, repeat steps a. through h. to install other thermocouple harness (3 or 4). WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

j.

Connect package cable to harness connector (7) per packager’s manual.

k.

Perform an operational check after completion of installation procedure per Chapter 7-3.7.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR INLET PRESSURE/TEMPERATURE (P2/T2) SENSOR REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500 SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Installation.... High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Removal.........

3 3


GEK 105054 Volume II WP 109 00 1.


Introduction. This work package contains instructions for removal and installation of the high pressure compressor (HPC) inlet pressure/temperature (P2/T2) sensor.

2.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Illustrated Parts Breakdown

GEK 105054 WP 002 00 GEK 105055

3.


4.


5.

Expendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). NomenclatureI

PB Figure No. / Item

Gasket

3-10




High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Removal. a.


b.

Disconnect pressure sensing tube from P2/T2 sensor pressure port per packager’s manual if installed. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

7.

c.

Disconnect electrical connector from P2/T2 sensor.

d.

Remove safety wire and remove bolts (figure 1) that secure P2/T2 sensor to adapter plate on compressor front frame (CFF). Retain bolts, if serviceable, for reuse.

e.

Remove gasket located between P2/T2 sensor and adapter plate. Inspect gasket for serviceability and replace if required.

f.

Remove P2/T2 sensor.

High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Installation. a.

Install gasket onto adapter plate between P2/T2 sensor and adapter plate.

b.

Using two bolts, secure P2/T2 sensor (figure 1) into adapter plate on CFF. Tighten bolts to 33-37 lb in. (3.7-4.2 N⋅m) of torque. Safety wire bolts. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

c.

Connect electrical connector to P2/T2 sensor. Tighten connector beyond finger tight (20 degrees maximum) until connecting parts are in solid contact without damage, then safety-wire.

d.

Connect pressure sensing tube to P2/T2 sensor pressure port per packager’s manual if installed.




Figure 1. High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor




WORK PACKAGE

TECHNICAL PROCEDURES LUBE SYSTEM TEMPERATURE SENSOR REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 8 ................... 0


Page

Lube System Temperature Sensor Installation................................................................. Lube System Temperature Sensor Removal......................................................................

7 3


GEK 105054 Volume II WP 110 00 1.


Introduction. This work package contains instructions for removal and installation of lube system temperature sensors for LM2500+ Model GK and GV gas generators and Model PK gas turbines. For LM2500+ Model PV power turbine applications, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title

For LM2500+ Models GK and GV gas generators and Model PK gas turbine: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Illustrated Parts Breakdown GEK 105055 For LM2500+ Model PV power turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

Support Equipment Required. None required.

4.


5.

Nomenclature

Specification

Lubricating Oil




Preformed Packing

65-2




Lube System Temperature Sensor Removal. a.

Comply with all instructions contained in WP 002 00. NOTE

•

Gas turbines with six stage power turbine (PK model), use a six element lube and scavenge pump. It has six RTD sensors. Five RTDs sense scavenge oil temperature from A-, B-, C-, and D-sumps and from accessory gearbox. One RTD senses lube oil supply line temperature. Procedure for replacement is same on all sensors.

•

Gas generators (GK and GV models) and gas turbines with two stage high speed power turbines (PV model), use a five element lube and scavenge pump. It has five RTD sensors. Four RTDs sense scavenge oil temperature from A-, B-, and C-sumps and from accessory gearbox. One RTD senses lube oil supply line temperature. Procedure for replacement is same on all sensors.

b.

Position approved waste container to catch residual oil, under RTD sensor to be removed.

c.

Remove RTD sensor as follows: (1)

Locate RTD sensor (figures 1, 2, and 3) to be removed.

(2)

If more than one RTD sensor is to be removed, tag RTD sensor electrical lead (1, figure 1) with sensor location information. WARNING

ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. CAUTION CARE SHOULD BE TAKEN NOT TO DAMAGE TIP OF RTD SENSOR. DAMAGED RTD SENSOR COULD ALLOW LUBE SYSTEM OVERHEATING. (3)

Disconnect and remove electrical lead (1) from RTD sensor (2) per packager’s manual.




Figure 1. Sump Scavenge and Lube Supply RTD Sensor Locations-GK, GV, and PV Models 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. Accessory Gearbox Scavenge RTD Sensor Location - All Models 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. Sump Scavenge and Lube Supply RTD Sensor Locations - PK Model




(4) d. 7.

•


•


Remove RTD sensor (2) and preformed packing (3). Discard preformed packing.

Repeat step c., as necessary, for other RTD sensors.

Lube System Temperature Sensor Installation. CAUTION CARE SHOULD BE TAKEN NOT TO DAMAGE TIP OF SENSOR. DAMAGED SENSOR COULD ALLOW LUBE SYSTEM OVERHEATING. NOTE

a.

•

Gas turbines with six stage power turbine (PK model), use a six element lube and scavenge pump. It has six RTD sensors. Five RTDs sense scavenge oil temperature from A-, B-, C-, and Dsumps and from accessory gearbox. One RTD senses lube oil supply line temperature. Procedure for replacement is same on all sensors.

•

Gas generators (GK and GV models) and gas turbines with two stage high speed power turbines (PV model), use a five element lube and scavenge pump. It has five RTD sensors. Four RTDs sense scavenge oil temperature from A-, B-, and C-sumps and from accessory gearbox. One RTD senses lube oil supply line temperature. Procedure for replacement is same on all sensors.

Install RTD sensor as follows: (1)

Determine RTD sensor location (figures 1, 2, and 3) and associated electrical lead for removed sensor.




LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (2)

Lubricate preformed packing (3, figure 1) with lubricating oil. Install preformed packing onto RTD sensor (2).

(3)

Install RTD sensor (2) into tube boss. Tighten RTD sensor to 135-155 lb in. (15.3-17.5 N⋅m) of torque. WARNING

ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. (4)

Connect electrical lead (1) to RTD sensor (2) per packager’s manual. Remove location tag, if attached.

b.

Repeat step a., as necessary, for all RTD sensors that have been removed.

c.

Perform leak check of RTD sensors after installation per Chapter 7-3.7.




WORK PACKAGE

TECHNICAL PROCEDURES ACCELEROMETER REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Accelerometer Installation.................................................................................................. Accelerometer Removal.......................................................................................................

7 3


GEK 105054 Volume II WP 111 00 1.


Introduction. This work package contains instructions for the installation and removal of the accelerometer(s) on LM2500+ Model GK and GV gas generators and LM2500+ Model PK gas turbine. For LM2500+ Model PV power turbine applications, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title

For LM2500+ Models GK and GV gas generators and Model PK gas turbine: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 For LM2500+ Model PV power turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


4.


5.

Nomenclature

Specification







Accelerometer Removal. a.


b.

Remove power to accelerometer(s) per packager’s manual.

c.

Remove packager supplied cable at accelerometer bracket and accelerometer panel per packager’s manual. CAUTION

d.

•

Ensure engine is not running when removing accelerometer(s), or damage due to excessive unmonitored vibration may occur.

•

Handle accelerometer integral lead with care to avoid damage.

Remove accelerometer (1, figure 1, view A) located on compressor rear frame (CRF) forward flange (7) as follows: (1)

Remove bolt (5, view B) and self-locking nut (8) that secures loop clamp (4) to loop clamp attached to B-sump oil scavenge tube.

(2)

Remove jamnut that secures integral accelerometer lead (10, view C) to accelerometer panel (9).

(3)

Remove four bolts (2, view A) and self-locking nuts (3) that secure accelerometer (1) to mounting bracket (6). Remove accelerometer.

(4)

If replacing accelerometer (1), remove loop clamps (4, view B) from integral accelerometer lead. Retain loop clamps for reinstallation onto new accelerometer.

(5)

If replacing accelerometer (1), remove instruction plate (14) from integral accelerometer lead (10) by removing self-locking strap (15).

(6)

If required, remove accelerometer mounting bracket (6, view A) and accelerometer panel (9, view C) as follows: (a) Remove three bolts (11, view A) and self-locking nuts (12) that secure accelerometer mounting bracket (6) to CRF forward flange (7). Remove accelerometer bracket.




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



(b) Remove safety wire and remove two bolts (13, figure 1) that secure accelerometer panel (9) to high pressure compressor (HPC) stage six stator case bosses. Remove accelerometer panel. NOTE The following step applies only to gas turbine with six stage power turbine installed. e.

Remove accelerometer mounted on turbine rear frame (TRF) forward flange as follows: (1)

Remove packager supplied cable at panel bracket per packager’s manual.

(2)

Remove jamnut that secures integral accelerometer lead (13, figure 2) to panel bracket (14). Remove integral lead connector from panel bracket. NOTE

Power turbine speed transducer lead (7) loop clamps are retained on power turbine, using bolts and nuts that secure integral accelerometer lead. Temporarily secure power turbine speed transducer lead out of way during integral accelerometer lead removal. (3)

Remove self-locking nut (12) and bolt (11) that secures loop clamps (9 and 10) to panel bracket (14). Using safety wire, temporarily secure loop clamp (9 or 10) that retains power turbine speed transducer lead (7) onto panel bracket.

(4)

Remove self-locking nut (12) and bolt (11) that secures loop clamps (9 and 10) to bracket (8). Using safety wire, temporarily secure loop clamp (9 or 10) that retains power turbine speed transducer lead (7) onto bracket.

(5)

Remove two self-locking nuts (4) and bolts (2) that secure bracket (6) to accelerometer (3). Move bracket, with power turbine speed transducer lead (7) attached, away from accelerometer and secure with safety wire. CAUTION

HANDLE ACCELEROMETER INTEGRAL LEAD WITH CARE TO AVOID DAMAGE. (6)

Remove two self-locking nuts (4) and bolts (2) that secure accelerometer (3) to mounting bracket (1). Remove accelerometer from mounting bracket.

(7)

If replacing accelerometer (3), remove loop clamps (9 or 10) from integral accelerometer lead (13). Retain loop clamps for reinstallation on new integral accelerometer lead.




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


7.


(8)

If replacing accelerometer (1), remove instruction plate (14) from integral accelerometer lead (10) by removing self-locking strap (15).

(9)

If required, remove accelerometer mounting bracket (1) by removing three self-locking nuts, bolts, and flat washers that secure accelerometer mounting bracket to TRF forward flange.

Accelerometer Installation. a.

Install accelerometer located on CRF forward flange as follows: (1)

If installed, inspect mounting bracket (6, figure 1, view A) bolts (11) and self-locking nuts (12) for tightness.

(2)

If installed, inspect accelerometer panel (9, view C) mounting bolts for tightness.

(3)

If required, install brackets as follows: (a) Apply thread lubricant, A50TF201, to threads of bolts (11). Using three bolts (11) and self-locking nuts (12), install mounting bracket (6) to CRF forward flange (7). Tighten bolts to 209-231 lb in. (23.6-26.1 N⋅m) of torque. (b) Using two bolts (13), install accelerometer panel (9, view C) onto HPC stator case stage six bosses. Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque and safety-wire.

(4)

Using four bolts (2, view A) and self-locking nuts (3), secure accelerometer (1) to mounting bracket (6). Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

(5)

If installing replacement accelerometer, install loop clamp (4, view B) onto integral accelerometer lead (10).

(6)

Using self-locking strap (15), install instruction plate (14) approximately 1.50 inches (38.1 mm) from threaded connection of integral accelerometer lead (10) for newly installed accelerometer (1).

(7)

Using bolt (5) and self-locking nut (8), secure loop clamp (4) to loop clamp attached to B-sump oil scavenge tube. Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(8)

Install integral accelerometer lead (10, view C) through accelerometer panel (9). Using jamnut, secure integral lead to accelerometer panel. Tighten jamnut to 25-30 lb in. (2.9-3.3 N⋅m) of torque.





Connect packager’s lead to accelerometer integral lead (10) per packager’s manual. NOTE

The following step applies only to gas turbine with six stage power turbines installed. b.

Install accelerometer mounted on TRF forward flange as follows: (1)

If required, lubricate threads of three bolts with thread lubricant, A50TF201, and install accelerometer mounting bracket (1, figure 2) using three bolts, flat washers, and self-locking nuts that secure accelerometer bracket to TRF forward flange. Tighten bolts to 85-90 lb in.(9.7-10.1 N⋅m) of torque.

(2)

Using two bolts (2, detail B) and self-locking nuts (4), secure accelerometer (3) to mounting bracket (1). Tighten bolts to 55-70 lb in.(6.3-7.9 N⋅m) of torque.

(3)

Remove safety wire that secures power turbine speed transducer lead (7).

(4)

Using two bolts (2) and self-locking nuts (4), secure bracket (6) and accelerometer (3) to accelerometer mounting bracket (1). Tighten bolts to 55-70 lb in.(6.3-7.9 N⋅m) of torque.

(5)

Install integral accelerometer lead (13, section A-A) onto panel bracket (14). Using jamnut, secure integral accelerometer lead to panel bracket. Tighten jamnut to 25-30 lb in. (2.9-3.3 N⋅m) of torque.

(6)

If installing replacement accelerometer, install loop clamps (9 or 10) onto integral accelerometer lead (13).

(7)

If installing replacement accelerometer, install instruction plate (14) approximately 1.50 inches (38.1 mm) from threaded connection of integral accelerometer lead (10) using self-locking strap (15).



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE Power turbine speed transducer lead loop clamps are retained on power turbine, using bolts and nuts that secure integral accelerometer lead (13) loop clamps. (8)

Using bolt (11, figure 2) and self-locking nut (12), secure loop clamps (9 and 10) to bracket panel (14). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(9)

Using bolt (11) and self-locking nut (12), secure loop clamps (9 and 10) to bracket (8). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

(10) Using bolt and self-locking nut, secure loop clamp (5) to bracket (6). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque. c.

Connect packager supplied cable and restore power to accelerometer (3) per packager’s manual.

d.

Perform an operational check after completion of accelerometer installation per Chapter 7-3.7.




WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE INLET PRESSURE (P5.4) PROBE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Power Turbine Inlet Pressure (P5.4) Probe Installation................................................... Power Turbine Inlet Pressure (P5.4) Probe Removal........................................................

3 3


GEK 105054 Volume II WP 112 00 1.


Introduction. This work package contains instructions for removal and installation of the power turbine inlet pressure (P5.4) probe on the turbine mid frame (TMF).

2.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices

GEK 105054 WP 002 00

3.


4.


5.

Nomenclature

Specification







Power Turbine Inlet Pressure (P5.4) Probe Removal. a.

Comply with all instructions contained in WP 002 00. NOTE There is one power turbine inlet pressure (P5.4) probe. It is located at approximately 6:00 o’clock position on turbine mid frame.

7.

b.

Disconnect manifold tube (6, figure 1) from power turbine inlet pressure P5.4 probe (3) per packager’s manual.

c.

Cut safety wire and remove coupling nut (2) from TMF boss (7). Remove P5.4 probe (3) from TMF.

Power Turbine Inlet Pressure (P5.4) Probe Installation. a.

Lightly coat TMF boss (7, figure 1) threads with thread lubricant. CAUTION PROBE SHALL BE INSTALLED WITH THREE TABS ON PROBE FLANGE INSERTED INTO THREE SLOTS IN MOUNTING BOSS. THIS SHALL ENSURE CORRECT POSITIONING OF PROBE WITH HOLES IN PROBE FACING FORWARD. IMPROPER INSTALLATION SHALL RESULT IN INACCURATE PRESSURE INDICATIONS.

b.

Carefully install P5.4 probe (3) into TMF boss (7). Ensure three locating tangs (4) are seated into three slots on TMF boss.

c.

Hold P5.4 probe (3) firmly in place and install coupling nut (2). Tighten coupling nut finger-tight.

d.

Ensure alignment flat (5) on P5.4 probe (3) faces forward. Tighten coupling nut (2) to 70-80 lb in. (8.0-9.0 N⋅m) of torque. Safety-wire coupling nut.

e.

Connect manifold tube (6) onto P5.4 probe (3) per packager’s manual.




Figure 1. Power Turbine Inlet Pressure (P5.4) Probe Replacement




WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR OUTSIDE PIPING AND WIRING REMOVAL AND INSTALLATION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 42 ................. 0


Page

Outside Piping and Wiring Removal and Installation. .....................................................

4


GEK 105054 Volume II WP 113 00 1.


Introduction. This work package provides instructions for the removal and installation of outside piping and wiring on LM2500+ Models GK and GV gas generator and the Model PV gas turbine. For additional information on LM2500+ Model GV gas generator and Model PV gas turbine interconnections with the two stage power turbine, consult GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Number

For LM2500+ Models GK and GV gas generators and Model PV gas turbine: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance WP 002 00 Variable Stator Vane Actuator Replacement WP 100 00 Fuel System Configuration WP 101 00 Five Element Lube and Scavenge Pump Replacement WP 102 00 Igniter Plug and Ignition Lead Replacement WP 103 00 Ignition Exciter Replacement WP 104 00 Gas Generator Speed Sensor Replacement WP 105 00 Thermocouple Probe (T5.4) and Harness Replacement WP 108 00 High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Replacement WP 109 00 Lube System Temperature Sensor Replacement WP 110 00 Accelerometer Replacement WP 111 00 Power Turbine Inlet Pressure (P5.4) Probe Replacement WP 112 00 Air/Oil Separator Replacement WP 116 00 Pneumatic Starter (Shrouded/Nonshrouded) Replacement WP 117 00 Hydraulic Starter Replacement SWP 117 01 Ultraviolet Flame Sensing System Components Replacement WP 118 00 Hydraulic Pump Replacement WP 120 00 Variable Stator Vane Servovalve Replacement WP 121 00 High Pressure Compressor Discharge Temperature T3 Sensor Replacement WP 123 00 Illustrated Parts Breakdown GEK 105055 For additional information on LM2500+ Model GV gas generator and Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053



Support Equipment. None Required.

4.



Lubricating Oil

MIL-L-23699 or MIL-L-7808 736L680G01 R297P04 (Alt) GE Spec A50TF201

Safety Cable Safety Wire Thread Lubricant 5.


Expendable Material. Due to the variety of gaskets, preformed packings, seals, etc. used during installation of external tubing, expendable materials are not listed. Refer to Illustrated Parts Breakdown (IPB), GEK 105055, for required parts.


GEK 105054 Volume II WP 113 00 6.


Outside Piping and Wiring Removal and Installation. a.


•

ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

•

IGNITION SYSTEM SHALL BE INOPERATIVE FOR AT LEAST 2 MINUTES BEFORE IGNITION LEAD IS DISCONNECTED. IGNITION SYSTEM COULD BE CHARGED WITH LETHAL HIGH VOLTAGE.

•


b.

Consult table 1 for work packages used to remove components that interact with outside piping and wiring.

c.

Consult table 2 and figure 1 for accessory gearbox (AGB) air and oil piping and wiring removal and installation placement and torquing values.

d.

Consult table 3 and figures 2, 3, and 4 for outside engine oil piping removal and installation placement and torquing values.

e.

Consult table 4 and figures 5, 6, 7, and 8 for outside engine air piping removal and installation placement and torquing values.

f.

Consult table 5 and figures 9, 10, and 11 for outside engine wiring removal and installation placement and torquing values.

g.

Consult packager’s manual for any packager supplied accessories removal and installation placement and torquing values.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Gas Generator Work Packages Component

Work Package

Off-Engine Connection

Variable Stator Vane (VSV) Actuators Fuel System Lube and Scavenge Pump Igniter Speed Sensor T5.4 Harness P2/T2 Electrical P2/T2 Pressure Lube System RTDs Accelerometer P5.4 Air/Oil Separator Pneumatic Starter Hydraulic Starter UV Flame Sensors Hydraulic Pump VSV Servovalve T3 Sensor

WP 100 00

Packager’s manual

WP 101 00 WP 102 00 WP 103 00 WP 105 00 WP 108 00 WP 109 00

Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual

WP 110 00 WP 111 00 WP 112 00 WP 116 00 WP 117 00 SWP 117 01 WP 118 00 WP 120 00 WP 121 00 WP 123 00



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Accessory Gearbox Air and Oil Piping and Wiring

Fig. 1

Index/ Sheet 1/1 2/1

11

Item Transfer Gearbox Assembly (TGB) Tube

Tube

Index/ Sheet

3/1

Loop Clamp

4 5

Bracket Bolt

30

Gasket

31

Bolt

65/2 66 67

Bracket Loop Clamp Bolt

6

Coupling Boss

7

9 10

Preformed Packing Preformed Packing Flat Washer Bolt

12 13 14

Air/Oil Separator Gasket Bolt

45/2

Cap

16

Adapter Tube

17

Fitting

75/3 76 77


19

Fitting

8

15

18

Hose

Hose

Use With Item

Torque

Note

AGB Scavenge 55-70 lb in. (6.3-7.9 N⋅m) AGB Scavenge 33-37 lb in. (3.8-4.1 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 100-110 lb in (11.3-12.4 N⋅m)

Safetywire boss, (c) (b) (b)

33-37 lb in. (3.8-4.1 N⋅m)

(c)

33-37 lb in. (3.8-4.1 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 54-64 lb ft (73.2-86.7 N⋅m) 54-64 lb ft (73.2-86.7 N⋅m)

(c)

55-70 lb in. (6.3-7.9 N⋅m) 450-550 lb in. (50.9-62.1 N⋅m)

Lube Supply

Lube Return



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Accessory Gearbox Air and Oil Piping and Wiring - (Cont.) Fig. 1

Index/ Sheet 18/1

24

28

32/2

34

Item Hose

Oil Manifold Tube

Hose

Hose

Hose

Index/ Sheet 20/1 21 22 23

Use With Item Mending Plate Loop Clamp Nut Bolt

74/3

Tube

25

Fitting

26 27

Loop Clamp Bolt

29

Fitting

24

Oil Manifold Tube

33/2

Fitting

46

Tee Tube

39 68 69 70 71

Hose Loop Clamp Nut Loop Clamp Bolt

35 36 37 38

Lube & Scavenge Pump Loop Clamp Nut Bolt

40 41

Loop Clamp Loop Clamp

Torque

Note

55-70 lb in. (6.3-7.9 N⋅m) 450-550 lb in. (50.9-62.1 N⋅m) 270-300 lb in. (30.6-33.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 650-770 lb in. (73.5-87.0N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Accessory Gearbox Air and Oil Piping and Wiring - (Cont.)

Fig. 1

Index/ Sheet 39/2 42

Item Hose Oil Tube

Index/ Sheet 64/2 43 44

Use With Item Loop Clamp Loop Clamp Bolt

72 73

Loop Clamp Fitting

46

Tee Tube

47

Oil Tube

47

Oil Tube

48 49 50 51

Bracket Nut Loop Clamp Bolt

58 60 61 62


63

Fitting

39 52 53

Hose Gasket Bolt

47

Oil Tube

55

Preformed Packing

48

54

Bracket

Oil Drain Tube

Torque

Note

33-37 lb in. (3.8-4.1 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m)

Starter Drain (b)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Accessory Gearbox Air and Oil Piping and Wiring - (Cont.) Fig.

Index/ Sheet

1

56/2

Item Hose

Index/ Sheet

Use With Item

Torque

57/2

Fitting

135-155 lb in. (15.3-17.5 N⋅m)

47

Oil Tube

135-155 lb in. (15.3-17.5 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m)

Note

58

Bracket

59

Bolt

78/3

Oil Tube

79/3

Preformed Packing

80

Check Valve

81

U-Bolt

82

Washer

83

Support

84

Nut

33-37 lb in. (3.8-4.1 N⋅m)

85

Swivel Tee

112-128 lb ft (151.9-173.5 N⋅m)

93

Fitting

112-128 lb ft. (151.9-173.5 N⋅m)

87

Preformed Packing

88

Check Valve

89

U-Bolt

90

Washer

91

Support

92

Nut

80

86

88

Check Valve

Oil Scavenge Tube

Check Valve

(b) 112-128 lb ft (151.9-173.5 N⋅m)

(b) 112-128 lb ft (151.9-173.5 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

Notes: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Lubricate preformed packing using lubricating oil. (b) Safety-wire item. 9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Accessory Gearbox (Sheet 1 of 3) 10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.








LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping Fig. 2

Index/ Sheet 1

Item A-Sump Oil Supply Hose

11

Oil Tube

12

Tube Cap

13

Oil Manifold

14

VSV Rod-End Hose

Index/ Sheet 2/1

Use With Item Bracket

3

Bolt

4 5 6

Cushion Clamp Bracket Bolt

7 8 9


10

Cushion Clamp

15 16

Preformed Packing Retainer

17

Nipple

18 19

24

Drain Can Preformed Packing Preformed Packing Safety Cable/Wire Preformed Packing Reducer

2/1

Bracket

3

Bolt

4 5

Cushion Clamp Bracket

20 21 22

3

VSV Head-End Hose

25

Hose

1/1

A-Sump Oil Supply Hose

23

Torque 450-550 lb in. (50.9-62.1 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

Note

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 450-550 lb in. (50.9-62.1 N⋅m) 270-300 lb in. (30.6-33.9 N⋅m) 650-770 lb in. (73.5-87.0 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m)

(b) (b) (b)

(b) (b)

135-155 lb in. (15.3-17.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 450-550 lb in. (50.9-62.1 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

(b) (b)



Fig. 3

Index/ Sheet 1/1

13 15

15 22

27

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping - (Cont.) Item A-Sump Oil Supply Hose

VSV Head-End Hose Hose

VSV Rod-End Hose VSV Rod-End Hose

VSV Drain Hose

Index/ Sheet 6/1

Use With Item Bolt

7 8 9


10 11

Cushion Clamp Nipple

12 14

Preformed Packing Tube Tee

16

Tube Tee

17 18

Bracket Bolt

19

Bolt

20 21

Angle Bracket Bracket

23 24

Preformed Packing Retainer

25

Nipple

26 28

33

Drain Can Preformed Packing Preformed Packing Safety Cable/ Wire Preformed Packing Reducer

35

Tube Tee

29 30 31

VSV Head-End Hose

34

Hose

36

Hose

32

Torque 55-70 lb in. (6.3-7.9 N⋅m)

Note

55-70 lb in. (6.3-7.9 N⋅m) 450-550 lb in. (50.9-62.1 N⋅m)

(b) (b)

450-550 lb in. (50.1-62.1 N⋅m) 270-300 lb in. (30.5-33.8 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)


(b)

135-155 lb in. (15.3-17.5 N⋅m)

(b)

(b) (b)

(b)


(b) (b)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping - (Cont.) Fig. 3

Index/ Sheet 37/1

41

44/2

4

1

Item Tube

Oil Manifold

Oil Tube

Oil Manifold

Index/ Sheet 38/1

Use With Item Cushion Clamp

39

Bolt

40 42

Nut Cushion Clamp

43

Bolt

45/2

Loop Clamp

46

Bolt

47 48 49

Nut Spray Shield Bolt

50 51 52 53 54

Nut Cushioned Clamp Spray Shield Angle Bracket Bolt

55 56 57 58

Nut Clamp Cushion Bracket Bolt

59 60 61 62

Nut Cushion Clamp Bracket Bolt

63 64 65 2

Nut Cushion Clamp Washer Angle Bracket

3

Bolt

4

Clamp


Note


33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

650-770 lb in. (73.5-87.0 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m) 15



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping - (Cont.)

Fig. 4

Index/ Sheet 5

21

33

Item Oil Manifold

Oil Tube

Oil Manifold

Index/ Sheet 6


7

Bolt

8 9

Nut Bolt

10 11 12 13

Nut Sleeve Spacer Cushion Clamp Bolt

14 15 16 17

Nut Loop Clamp Support Bracket Bolt

18 19 20 22

Nut Loop Clamp Spray Shield Cushion Clamp

23

Bolt

24 25 26 27

Nut Cushion Clamp Angle Bracket Bolt

28 29 30

Nut Loop Clamp Bolt

31 32 34

Nut Loop Clamp Cushion Clamp

35

Bolt

36 37 38

Nut Sleeve Spacer Bracket


Note

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

112-128 lb ft (151.9-173.5 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

112-128 lb ft (151.9-173.5 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping - (Cont.) Fig. 4

Index/ Sheet 33

45

Item Oil Manifold

Oil Tube

58

Oil Tube

59

C-Sump Scavenge Tube

70

Tee Tube

Index/ Sheet 39 40

Use With Item Cushion Clamp Bolt

41 42 43 46

Flat Washer Nut Gasket Clamp Guide

47 48

Loop Clamp Bolt

49 50 51

Shoulder Washer Nut Bolt

52 53 54

Nut Bracket Bolt

55 56 57

Nut Loop Clamp Spray Shield

Torque

Note

55-70 lb in. (6.3-7.9 N⋅m)

450-550 lb in. (50.9-62.1 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

450-550 lb in. (50.9-62.1 N⋅m) 60 61

C-Sump Scavenge Bracket Bolt

62 63 64 65 66 67

Nut Shoulder Washer Loop Clamp Clamp Guide Loop Clamp Bolt

68 69

Nut Gasket

55-70 lb in. (6.3-7.9 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

270-300 lb in. (30.6-33.9 N⋅m) 17



Fig. 4

Index/ Sheet 71

83

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping - (Cont.) Item B- and C-Sump Drain Tube

B-Sump Supply Oil Tube

100

Hose

101

Hose

Index/ Sheet 72

Use With Item Bolt

73 74 75 76

Cushion Clamp Nut Drain Bracket Bolt

77 78 79 80

Nut Cushion Clamp Bracket Bolt

81 82 84

Nut Cushion Clamp Loop Clamp

85

Bolt

86 87 88 89

Nut Spray Shield Bracket Bolt

90 91 92 93

Nut Loop Clamp Bracket Bolt

94 95 96 97 98

Nut Cushion Clamp Spray Shield Spray Shield Bolt

99

Safety Cable/Wire

Torque 33-37 lb in. (3.7-4.1 N⋅m)

Note

33-37 lb in. (3.7-4.1 N⋅m)

33-37 lb in. (3.7-4.1 N⋅m)

450-550 lb in. (50.9-62.1 N⋅m) 33-37 lb in. (3.7-4.1 N⋅m)

33-37 lb in. (3.7-4.1 N⋅m)

33-37 lb in. (3.7-4.1 N⋅m)

33-37 lb in. (3.7-4.1 N⋅m)

112-128 lb ft (151.9-173.5 N⋅m) 112-128 lb ft (151.9-173.5 N⋅m)




Table 3. Outside Engine Oil Piping - (Cont.) Notes: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Lubricate preformed packing using lubricating oil. (b) Safety-wire item.




Figure 2. Right-Side Engine Oil Piping 20 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. Left-Side Engine Oil Piping (Sheet 1 of 2) 21 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. Left-Side Engine Oil Piping (Sheet 2 of 2) 22 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 4. Bottom Engine Oil Piping 23 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Outside Engine Air Piping

Fig. 5

Index/ Sheet 1/1

8

Item Air Manifold

Air/Oil Separtor Seal-Pressure Hose

14

27

Sump Vent Manifold

Ejector Nozzle

Index/ Sheet 2/1 3 4 5

Use With Item Bracket Cushion Strap Bracket Bolt

6

Bolt

7 9

Gasket Preformed Packing

10

Reducer

11 12 13

Safety Cable Preformed Packing Nipple

15

Bolt

16 17 18 19

Gasket Safety Cable Tube Bracket Bolt

20 21 22

Retaining Strap Bracket Bolt

23 24 25

Cushion Strap Bracket Bolt

26 28

Cushion Strap Bolt

29 30 31

Nut Gasket V-band Clamp

32

Tube Screen

Torque

Note

55-70 lb in. (6.3-7.9 N⋅m) 100-130 lb in. (11.3-14.6 N⋅m)

450-550 lb in. (50.9-62.1 N⋅m)

450-550 lb in. (50.9-62.1 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

(c)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

40 lb in. (4.5 N⋅m)

(a)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Outside Engine Air Piping - (Cont.) Fig. 5

Index/ Sheet 27/1

44/2

44

54

Item Ejector Nozzle

Air Tube

Air Tube

Stage 9 Air Tube

Index/ Sheet 33/1 34

Use With Item Support Bracket Bolt

35

Bolt

36 37 38 39

Retaining Strap Safety Cable Support Bracket Bolt

40 41

Cushion Strap Bolt

42 43 45/2

Nut Gasket Bolt

46 47 48 49

Gasket Safety Cable/Wire Manifold Bracket Bolt

50 51

Retaining Strap Bolt

52

Nut

53 55

Gasket Bolt

56 57 58 59

Gasket Safety Cable/Wire Support Bracket Bolt

60

Retaining Strap

Torque

Note

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 100-130 lb in. (11.3-14.6 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

(c)


Safetywire bolt, (c)

55-70 lb in. (6.3-7.9 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Outside Engine Air Piping - (Cont.)

Fig. 5

Index/ Sheet 54/2

66

76

86

Item Stage 9 Air Tube

High Pressure (HP) Recoup Air Manifold (Right)

HP Recoup Air Manifold (Right)

Stage 13 Air Tube

Index/ Sheet 61/2

Use With Item Bolt

62 63 64

Retaining Strap Bolt Nut

65 67

Gasket Bolt

68

Nut

69 70 71

Gasket Boss Seal Machine Plug

72

Bolt

73

Nut

74 75 77

Gasket Metering Spacer Bracket

78

Bolt

79 80 81 82

Nut Retaining Strap Bracket Bolt

83 84 85

Nut Retaining Strap V-band Clamp

87

Air Elbow

88

Bolt

89

Gasket

Torque 55-70 lb in. (6.3-7.9 N⋅m)

Note



33-37 lb in. (3.7-4.1 N⋅m)

33-37 lb in. (3.7-4.1 N⋅m)

40 lb in. (4.5 N⋅m) 36-38 lb ft (48.9-51.5 N⋅m) 55-70 lb in. (6.2-7.9 N⋅m)

(a) (d)




Index/ Sheet 86/2

94

102

115


Stage 13 Air Tube

Stage 9 Cooling Air Tube

C-Sump Vent Tube

Index/ Sheet 90/2


91

Bolt

92 93 95

Nut Retaining Strap Bracket

96

Bolt

97 98 99 100

Nut Retaining Strap Air Elbow Bolt

101 103

Gasket Bolt

104

Nut

105 106

Gasket Bolt

107

Nut

108 109 110

Support Bracket Support Bracket Machine Bolt

111 112


113

Nut

114 116

Gasket Bolt

117 118 119

Nut Gasket Bolt

Torque

Note

33-37 lb in. (6.3-7.9 N⋅m)

36-38 lb ft (48.9-51.5 N⋅m) 33-37 lb in. (3.7-4.1 N⋅m)

(d)



55-70 lb in. (6.3-7.9 N⋅m) 27




Fig. 5

Index/ Sheet 115/2

125

6

1/1

13/2

Item Air Vent Manifold

Stage 13 Air Manifold


Stage 9 Stage Air Manifold

Index/ Sheet 120/2

Use With Item Retaining Strap

121

Bolt

122 123 124

Retaining Strap Elastic Joint Hose Clamp

126

Bracket

127

Bolt

128 129 130

Nut Strap Bolt

131 132 133 134

Washer Nut Retaining Strap V-band Clamp

2/1

Bolt

3 4 5

Gasket Safety Wire Bolt

6 7 8 9

Nut Gasket Bracket Bolt

10 11

Tiedown Strap Bolt

12 14/2

Gasket Bolt

15

Retaining Strap

Torque

Note

55-70 lb in. (6.3-7.9 N⋅m)

34-36 lb in. (3.9-4.0 N⋅m) 36-38 lb ft (48.9-51.5 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m)

(d)

55-70 lb in. (6.3-7.9 N⋅m)

45 lb in. (5.0 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

(a) Safetywire bolt, (c)

100-130 lb in. (11.3-14.6 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

Safetywire bolt,(c)

55-70 lb in. (6.3-7.9 N⋅m)




Index/ Sheet 13/2

19

23

41

45

Item Stage 9 Air Manifold

Rear Frame Vent Leakage Tube




Index/ Sheet 16/2

Use With Item Bolt

17 18 20

Nut Gasket Bolt

21 22 24

Nut Metering Spacer Flat Bracket

25 26

Angle Bracket Bolt

27 28 29 30


31 32 33

Nut Clamp Bolt

34 35 36 37

Nut Loop Clamp Manifold Bracket Bolt

38 39 40 42

Nut Retaining Strap Manifold Bracket Bolt

43 44 46

Nut Gasket Bolt

47 48

Nut Gasket

Torque 55-70 lb in. (6.3-7.9 N⋅m)

Note

55-70 lb in. (6.3-7.9 N⋅m)

36-38 lb ft (48.9-51.5 N⋅m)

(d)

55-70 lb in. (6.3-7.9 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)




Fig. 6

Index/ Sheet 49/2

57

61

69 71

7

1



Stage 13 Air Tube

HP Recoup Air Manifold Stage 13 Manifold

Sump Vent Air Manifold

Index/ Sheet 50/2

Use With Item Elbow

51

Bolt

52 53 54

Gasket Bracket Bolt

55 56 58

Nut Retaining Strap Bolt

59 60 62

Nut Gasket Elbow

63

Bolt

64 65 66

Gasket Bracket Bolt

67 68 70

Nut Retaining Strap V-band Clamp

72

V-band Clamp

73

Bolt

74 75 2

Nut Retaining Strap Bracket

3

Bolt

4

Cushion Strap

Torque 36-38 lb ft (48.9-51.5 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

Note (d)

33-37 lb in. (3.7-4.1 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

36-38 lb ft (48.9-51.5 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

(d)

33-37 lb in. (3.7-4.1 N⋅m)

40 lb in. (4.5 N⋅m) 37 lb in. (4.8 N⋅m) 45 lb in. (5.0 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

(a) (d) (a)

55-70 lb in. (6.3-7.9 N⋅m)




Index/ Sheet 1

11

17

8

1

5

Item Sump Vent Air Manifold

A-Sump Vent Flex Hose

B-Sump Vent Tube & Hose

Rear Frame Vent Leakage Tube

HP Recoup Air Manifold

Index/ Sheet 5


6

Bolt

7 8 9


10 12

Cushion Strap Bolt

13 14

Gasket Bolt

15 16 18

Nut Gasket Bolt

19 20 21

Nut Gasket Bolt

22 23 2

Nut Gasket Bolt

3 4 6

Nut Metering Spacer Bolt

7 8 9 10

Nut Gasket Seal Machine Plug

11

Bolt

12 13 14

Nut Gasket Metering Spacer

Torque

Note

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

(c)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

180-200 lb in. (20.3-22.5 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)




Fig. 8

Index/ Sheet 15

Item HP Recoup Air Tube

Index/ Sheet 16

Use With Item Tube Bracket

17

Bolt

18 19 20 21


22 23

Nut Retaining Strap

Torque

Note

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

Notes: (a) Tighten and torque V-band clamp nut as follows: 1. Tighten nut to 50 percent of specified final torque. Check to ensure V-band clamp is seated equally over flanges around periphery and seal, if applicable, is properly seated. 2. Using plastic or non-metallic mallet, lightly tap around circumference of V-band clamp to equally distribute band tension. 3. Increase torque towards specified final torque value while lightly tapping V-band circumference, as necessary, to prevent unequal loading. 4. After application of specified final torque is reached, tap around V-band clamp circumference. 5. Reapply specified final torque. (b) Safety-wire item. (c) Lubricate with thread lubricant.




Figure 5. Right-Side Engine Air Piping (Sheet 1 of 2) 33 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 5. Right-Side Engine Air Piping (Sheet 2 of 2) 34 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 6. Left-Side Engine Air Piping (Sheet 1 of 2) 35 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 6. Left-Side Engine Air Piping (Sheet 2 of 2) 36 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 7. Top Engine Air Piping 37 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 8. Bottom Engine Air Piping 38 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. Outside Engine Wiring Fig. 9

Index/ Sheet 1

4

8

10

1 2

11

1

Index/ Sheet 2

Use With Item Support Bracket

3

Bolt

T3 Sensor

5

Bolt

Igniter Lead

6 7 9 10

Gasket Safety Cable Igniter Adapter Plug Bolt

11 12 13 14 15

Flat Washer Igniter Plug Seal Metal Ring Cushion Clamp Bolt

3 2 3

Tiedown Strap Bracket Bolt

4 5 6 7 8

Nut Plate Tiedown Strap Cushion Clamp Bolt

Item T2 - VSV Harness

T2 - VSV Harness Plate Accelerometer

Torque Note T2 - Per Packager’s Manual VSV - 20 degrees beyond finger-tight 55-70 lb in. (6.2-7.9 N⋅m) 55-70 lb in. (6.2-7.9 N⋅m)

23-27 lb ft (31-37 N⋅m) 55-70 lb in. (6.2-7.9 N⋅m)

(a) (a)

55-70 lb in. (a) (6.2-7.9 N⋅m) T2 VSV - 20 degrees beyond finger-tight

55-70 lb in. (6.2-7.9 N⋅m)

55-70 lb in. (6.2-7.9 N⋅m)

9 Nut Note: (a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.




Figure 9. Right-Side Engine Wiring 40 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 10. Left-Side Engine Wiring 41 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 11. Bottom Engine Wiring 42 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.




TECHNICAL PROCEDURES GAS TURBINE OUTSIDE PIPING AND WIRING REMOVAL AND INSTALLATION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 28 ................. 0 Alphabetical Index Page

Subject Outside Piping and Wiring Removal and Installation. .....................................................

4




Introduction. This subordinate work package provides instructions for the removal and installation of outside piping and wiring on the LM2500+ Model PK gas turbine.

2.


Number

Operation and Maintenance Manual, Volume II General Maintenance Variable Stator Vane Actuator Replacement Fuel System Configuration Six Element Lube and Scavenge Pump Replacement Igniter Plug and Ignition Lead Replacement Gas Generator Speed Sensor Replacement Thermocouple Probe (T5.4) and Harness Replacement High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Replacement Lube System Temperature Sensor Replacement Accelerometer Replacement Power Turbine Inlet Pressure (P5.4) Probe Replacement Fuel Pump Replacement Air/Oil Separator Replacement Pneumatic Starter (Shrouded/Nonshrouded) Replacement Hydraulic Starter Replacement Ultraviolet Flame Sensing System Components Replacement Hydraulic Pump Replacement Variable Stator Vane Servovalve Replacement T3 Sensor Replacement Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 100 00 WP 101 00 WP 102 01 WP 103 00 WP 105 00 WP 108 00 WP 109 00 WP 110 00 WP 111 00 WP 112 00 WP 115 00 WP 116 00 WP 117 00 SWP 117 01 WP 118 00 WP 120 00 WP 121 00 WP 123 00 GEK 105055




4.



Lubricating Oil

MIL-L-23699 or MIL-L-7808 736L680G01 R297P02 (Alt) GE Spec A50TF201

Safety Cable Safety Wire Thread Lubricant 5.


Expendable Material. Due to the variety of gaskets, preformed packings, seals, etc. used during installation of external tubing, expendable materials are not listed. Refer to Illustrated Parts Breakdown (IPB), GEK 105055, for required parts.




Outside Piping and Wiring Removal and Installation. a.


•


•


•


b.

Consult table 1 for work packages used to remove components that interact with outside piping and wiring.

c.

Consult table 2 and figure 1 for accessory gearbox air and oil piping and wiring removal and installation placement and torquing values.

d.

Consult table 3 and figures 2, 3, 4, and 5 for outside engine oil piping removal and installation placement and torquing values.

e.

Consult table 4 and figures 2, 3, 4, and 5 for outside engine air piping removal and installation placement and torquing values.

f.

Consult table 5 and figures 2, 3, 4, and 5 for outside engine wiring removal and installation placement and torquing values.

g.

Consult packager’s manual for any packager supplied accessories removal and installation placement and torquing values.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Gas Generator Work Packages Component

Work Package

Off-Engine Connection

VSV Actuators Fuel System Lube and Scavenge Pump Igniter Speed Sensor T5.4 Harness P2/T2 Electrical P2/T2 Pressure Lube System RTDs Accelerometer P5.4 Fuel Pump Air/Oil Separator Pneumatic Starter Hydraulic Starter UV Flame Sensors Hydraulic Pump VSV Servovalve T3 Sensor

WP 100 00 WP 101 00 SWP 102 01 WP 103 00 WP 105 00 WP 108 00 WP 109 00 WP 110 00 WP 111 00 WP 112 00 WP 115 00 WP 116 00 WP 117 00 SWP 117 01 WP 118 00 WP 120 00 WP 121 00 WP 123 00

Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual Packager’s manual



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Accessory Gearbox Air and Oil Piping and Wiring

Fig. 1

Index/ Sheet 1/1 2

7

Item Transfer Gearbox Assembly (TGB) Cover Plate

TGB Scavenge Tube

10

14

Air/Oil Separator Scavenge Tube

Lube Supply Hose

Index/ Sheet

Use With Item

3/1 4 5 6

Bracket Gasket Seal Washers Bolt

3

Bracket

8 9

Loop Clamp Bolt

29 30

Gasket Bolt

64/2 65 66


11/1

Air/Oil Separator

12 13

Gasket Bolt

37/2 38 39

Loop Clamp Nut Bolt

40 41 42

Loop Clamp Nut Bolt

74 75

Seal Gasket Bolt

15/1

Adapter Tube

16

Fitting

77/3 78

Bracket Loop Clamp

Torque

33-37 lb in. (3.8-4.1 N⋅m)

Note

(a)

55-70 lb in. (6.3-7.9 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

(a)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m) 54-64 lb ft (73.2-86.7 N⋅m) 54-64 lb ft (73.2-86.7 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Accessory Gearbox Air and Oil Piping and Wiring- (Cont.) Fig. 1

Index/ Sheet 14/1

17

23

27 31/2

33

Item Lube Supply Hose

Lube Return Hose

AGB Oil Supply Manifold Tube

TGB Lube Supply Hose Drain Manifold Hose

AGB Scavenge Hose

Index/ Sheet 15

Use With Item Adapter Tube

16

Fitting

18

Fitting

19 20 21 22

Mending Plate Loop Clamp Nut Bolt

76/3

Tube

24/1

Fitting

25 26

Loop Clamp Bolt

28

Fitting

32/2 23

Lube & Scavenge Pump Fitting

45

Tee Tube

69 38 39

Loop Clamp Nut Bolt

32

68

Lube & Scavenge Pump Loop Clamp Preformed Packing Plug

35

Loop Clamp

63 67

34

Oil Manifold Tube

Torque 112-128 lb ft (151.9-173.5 N⋅m) 200-300 lb. in (22.6-33.9 N⋅m) 450-550 lb in. (50.9-62.1 N⋅m)

Note

Lube Return


135-155 lb in. (15.3-17.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 54-64 lb ft (73.3-86.7 N⋅m) (b) 135-155 lb in. (15.3-17.5 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Accessory Gearbox Air and Oil Piping and Wiring- (Cont.)

Fig. 1

Index/ Sheet 34/2

Item Oil Manifold Tube

Index/ Sheet 36/2

Use With Item Bolt

Torque 33-37 lb in. (3.8-4.1 N⋅m)

73

Fitting

135-155 lb in. (15.3-17.5 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

43

Bracket

44

Bolt

45 46

Tee Tube Drain Manifold Oil Tube

47

Bracket

48 49 50

Nut Loop Clamp Bolt

57 59 60 61


62

Fitting

51 52

Gasket Bolt Preformed Packing Preformed Packing Bolt

47

Bracket

53

Oil Drain Tube

54

55

Oil Drain Hose

56

57

Bracket

58

80/3

Lube Supply Oil Tube

81/3 82

Preformed Packing Check Valve

Note

(a)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m) (b) (b) 33-37 lb in. (3.8-4.1 N⋅m) (b) 112-128 lb ft (151.9-173.5 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Accessory Gearbox Air and Oil Piping and Wiring- (Cont.) Fig. 1

1

Index/ Sheet 82/3

88 90

Item Lube Supply Check Valve

Oil Scavenge Discharge Tube Lube Scavenge Check Valve

Index/ Sheet 83/3

Use With Item U-Bolt

84 85 86

Washer Support Nut

87

Swivel Tee

89 91

Preformed Packing U-Bolt

92 93 94

Washer Support Nut

Torque

Note

33-37 lb in. (3.8-4.1 N⋅m) 112-128 lb ft (151.9-173.5 N⋅m) (b)

33-37 lb in. (3.8-4.1 N⋅m)

Notes: (a) Safety-wire item. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (b) Lubricate preformed packing using lubricating oil.












LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping Fig. 2

Index/ Sheet 1/1

Hose

5

Hose

7

B-Sump Scavenge Oil Tube

21

2

Item

26

Oil Tube

Oil Manifold

Index/ Sheet 2/1


3

Bolt

4 6

Nut Cushion Clamp

8

Machine Plug

9 10 11

Preformed Packing Angle Bracket Bolt

12 13 14 15 16 17

Nut Sleeve Spacer Cushion Clamp Cushion Clamp Angle Bracket Bolt

18 19 20 22

Washer Nut Gasket Cushion Clamp

23

Machine Plug

24 25 27

Preformed Packing Loop Clamp Cushion Clamp

28

Bolt

29 30

Nut Bolt

31 32 33

Nut Cushion Clamp Bolt

34

Nut


Note

112-128 lb ft (151.9-173.5 N⋅m) 112-128 lb ft (151.9-173.5 N⋅m) (a) 33-37 lb in. (3.8-4.1 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

650-770 lb in. (73.5-87.0 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m)

D-Sump Scavenge (a)

450-550 lb in. (50.9-62.1 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m) 13



Fig. 2

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping- (Cont.)

Index/ Sheet 26/1

Item Oil Manifold

37

Oil Tube

52

Hose Assembly

53

Oil Manifold

54

Oil Tube

Oil Tube

Index/ Sheet 35/1 36 38

Use With Item Loop Clamp Spray Shield Clamp Cushion

39

Machine Plug

40 41 42

Preformed Packing Angle Bracket Bolt

43 44 45 46

Nut Clamp, Loop Support Bracket Bolt

47 48 49

Nut Loop Clamp Bolt

50 51

Nut Clamp Loop

55

Lube Bracket

56

Bolt

57 58 59 60 61 62 64

Shoulder Washer Nut Loop Clamp Clamp Guide Lube Bracket Clamp Loop Loop Clamp

65

Bolt

66 67

Nut Spray Shield

Torque

Note

112-128 lb ft (151.9-173.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) (a) 33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

112-128 lb ft (151.9-173.5 N⋅m) 54-64 lb ft (73.3-86.7 N⋅m) 650-770 lb in. (73.5-87.0 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m)

450-550 lb in. (50.9-62.1 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m)


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping- (Cont.) Fig. 2

Index/ Sheet 68

Item Oil Manifold

Index/ Sheet 69

Use With Item Loop Clamp

68/1

Oil Manifold

70/1

Bolt

71 72

Nut Bolt

73 74 75 76 77

Shoulder Washer Nut Clamp Loop Clamp Guide Bolt

78 79 80

Nut Clamp Loop Bolt

81 82 83


Oil Tube 85/2

D-Sump Lube Oil Supply Tube

86/2

Angle Bracket

87

Bolt

88 89 90 91 92 93

Shoulder Washer Nut Clamp Loop Clamp Guide Angle Bracket Bolt

94 95 96 97

Nut Loop Clamp Flat Washer Tube Cap

98

Bolt

99 100 101




Note

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)


33-37 lb in. (3.8-4.1 N⋅m)

450-550 lb in. (50.9-62.1 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Outside Engine Oil Piping- (Cont.)

Index/ Sheet 102/2

Fig. 2

Item D-Sump Scavenge Tube

Index/ Sheet 103/2

Use With Item Angle Bracket

104

Bolt

105 106 107 108 109 110

Shoulder Washer Nut Clamp Loop Clamp Guide Bracket Bolt

111 112 113 114

Nut Loop Clamp Bracket Bolt

115 116 117

Nut Loop Clamp Tube Cap


Note

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

650-770 lb in. (73.5-87.0 N⋅m)

Notes: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Lubricate preformed packing using lubricating oil.




Figure 2. Engine Oil Piping (Sheet 1 of 2) 17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. Engine Oil Piping (Sheet 2 of 2) 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Outside Engine Air Piping Fig. 3

Index/ Sheet 1

18

Item Ejector Nozzle

Pressurization Hose

30 31

Support Bracket Manifold Bracket

34

Support Bracket

Index/ Sheet 2

Use With Item Bolt

3 4 5 6


7 8 9


10

Bolt

11 12 13

Retaining Strap Safety Wire V-band Clamp

14 15

Screen Bolt

16 17 19

Nut Gasket Bolt

20 21 22 23


24

Bolt

25 26 27

Cushion Strap Safety Wire Bolt

28 29

Nut Gasket

32

Bolt

33 35


36

Retaining Strap

Torque 100-130 lb in. (11.3-14.6 N⋅m)

Note

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

40 lb in. (4.5 N⋅m)

Safety-wire bolt, (b)

(a)

55-70 lb in. (6.3-7.9 N⋅m)

100-130 lb in. (11.3-14.6 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

(b)

100-130 lb in. (11.3-14.6 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m) 19



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Outside Engine Air Piping- (Cont.)

Fig. 3

Index/ Sheet 37

53

Item Pressurization Air Tube

C-Sump Vent Tube

Index/ Sheet 38

Use With Item Support Bracket

39

Bolt

40 41 42

Retaining Strap Support Bracket Bolt

43 44 45


46 47 48


49 50


51 52 54

Nut Gasket Elastic Joint

55

Hose Clamp

56 57

Bracket Bolt

58 59 60


61 62

Strap Retaining Bolt Gasket Nut Bolt

65

Tube Bracket

63 64 66

68

Tube Bracket

67 69


70

Strap Retaining

Torque

Note

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 100-130 lb in. (11.3-14.6 N⋅m)

34-36 lb in. (3.9-4.0 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Outside Engine Air Piping- (Cont.) Fig. 4

Index/ Sheet 1

11

19 5

1

Item 13th Stage Air Tube

13th Stage Air Manifold

Manifold Bracket Balance Piston Air Tube

Index/ Sheet 2


3

Bolt

4 5 6


7 8


9 10 12

Nut Gasket Retaining Strap

13

Bolt

14 15 16


17 18

Nut V-band Clamp

20

Bolt

21 2


3 4 5 6

Nut Metal Gasket Seal Retainer Bolt

7 8 9

Retaining Strap Air Tube Bracket Bolt

10 11


12 13

Nut Gasket

Torque

Note

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

36-38 lb ft. (48.9-51.5 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

(c)

33-37 lb in. (3.8-4.1 N⋅m) 45 lb in. (5.1 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

(a)

100-130 lb in. (11.3-14.6 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Outside Engine Air Piping- (Cont.)

Fig. 5

Index/ Sheet 1 15

35

Item Balance Piston Air Tube D-Sump Vent Tube

D-Sump Pressurization Tube

Index/ Sheet 14

Use With Item Orifice Plate

16

Angle Bracket

17

Bolt

18 19 20 21

Nut Retaining Strap Tube Bracket Bolt

22 23 24 25


26 27 28 29


30 31 32


33 34 36

Gasket Safety Cable Support Bracket

37

Bolt

38 39


40 41 42

Nut Metal Gasket Seal Retainer

Torque

Note

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

33-37 lb in. (3.8-4.1 N⋅m)

55-70 lb in. (6.3-7.9 N⋅m)

Safety-wire bolt, (b)

55-70 lb in. (6.3-7.9 N⋅m) 100-130 lb in. (11.3-14.6 N⋅m)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Outside Engine Air Piping- (Cont.) Index/ Sheet

Fig.

Item

Index/ Sheet

Use With Item

Torque

Note

Notes: (a) Tighten and torque V-band clamp nut as follows: 1. Tighten nut to 50 percent of specified final torque. Check to ensure V-band clamp is seated equally over flanges around periphery and seal, if applicable, is properly seated. 2. Using plastic or non-metallic mallet, lightly tap around circumference of V-band clamp to equally distribute band tension. 3. Increase torque towards specified final torque value while lightly tapping V-band circumference, as necessary, to prevent unequal loading. 4. After application of specified final torque is reached, tap around V-band clamp circumference. 5. Reapply specified final torque. (b) Safety-wire item. (c) Lubricate with thread lubricant.




Figure 3. Right Side Engine Air Piping 24 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 4. Left Side Engine Air Piping 25 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 5. Engine Air Piping, Power Turbine 26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. Outside Engine Wiring Fig. 6

Index/ Sheet 1 2 4

Item Support Bracket Plate Cushion Clamp

Index/ Sheet

Use With Item

3 5

Tiedown Strap Bolt

6

Nut

Torque

Note

55-70 lb in. (6.3-7.9 N⋅m)




Figure 6. Engine Wiring 28 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES VARIABLE STATOR VANE TORQUE SHAFT REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Variable Stator Vane Torque Shaft Installation. .............................................................. Variable Stator Vane Torque Shaft Removal. ...................................................................

5 3


GEK 105054 Volume II WP 114 00 1.


Introduction. This work package provides instructions for the removal and installation of the variable stator vane (VSV) torque shaft.

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Variable Stator Vane Actuator Replacement

GEK 105054 WP 002 00 WP 100 00


Part No.

Sling, Nylon

Local Purchase


Specification







Variable Stator Vane Torque Shaft Removal. a.

Comply with all instructions contained in WP 002 00. NOTE There are two variable stator vane torque shafts; removal is same for both.

b.

Remove VSV actuator (10, figure 1) per WP 100 00. CAUTION INPUT RODS ARE INTEGRAL TO VSV TORQUE SHAFT. IF REPLACEMENT OF ANY INPUT ROD IS REQUIRED, ENTIRE VSV TORQUE SHAFT SHALL BE REPLACED.

c.

Disconnect input rods (5) from connecting links (6) as follows: NOTE Inlet guide vane (IGV) input rod connection to connecting link is located in opposite direction of other VSV stages.

d.

(1)

Remove bolt (2), flat washer (3), and nut (4) that connect IGV input rod (5) to IGV connecting link (6).

(2)

Remove bolt (2), flat washer (3), and nut (4) that connect VSV stage 0 through stage 6 input rods (5) to VSV stage 0 through stage 6 connecting links (6).

Remove VSV torque shaft (8) from high pressure compressor (HPC) stator case as follows: CAUTION VSV TORQUE SHAFT WEIGHS APPROXIMATELY 100 LBS (45.3 KG). ENSURE VSV TORQUE SHAFT IS PROPERLY SUPPORTED DURING REMOVAL TO PREVENT ACCIDENTAL DAMAGE DUE TO DROPPING. (1)

Attach overhead hoist to nylon sling.

(2)

Attach nylon sling to VSV torque shaft (8).

(3)

Remove safety wire and remove four bolts (1) that secure forward mounting bracket (7) to HPC stator case.

(4)

Remove safety wire and remove four bolts (1) that secure aft mounting bracket (9) to HPC stator case.




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


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION

ENSURE VSV INPUT RODS ARE NOT BENT OR BROKEN DURING REMOVAL FROM HPC STATOR CASE, OR REPLACEMENT OF ENTIRE VSV TORQUE SHAFT SHALL BE REQUIRED. (5) 7.

Using nylon sling and overhead hoist, remove VSV torque shaft (8) from HPC stator case.

Variable Stator Vane Torque Shaft Installation. CAUTION

a.

•

VSV torque shaft input rod length is nonadjustable.

•

Improper VSV torque shaft input rod length could cause off-schedule VSV operation resulting in compressor stall.

•

Input rods are integral to VSV torque shaft. If replacement of any input rod is required, entire VSV torque shaft shall be replaced.

Inspect VSV torque shaft input rods (5, figure 1) for safety-wire installation. Replace VSV torque shaft (8) if safety wire is missing from any input rod. CAUTION VSV TORQUE SHAFT WEIGHS APPROXIMATELY 100 LBS (45.3 KG). ENSURE VSV TORQUE SHAFT IS PROPERLY SUPPORTED DURING REMOVAL TO PREVENT ACCIDENTAL DAMAGE DUE TO DROPPING.

b.

Install VSV torque shaft (8) onto HPC stator case as follows: (1)

Attach overhead hoist to nylon sling.

(2)

Attach nylon sling to VSV torque shaft (8).




USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE VSV INPUT RODS ARE NOT BENT OR BROKEN DURING INSTALLATION ONTO HPC STATOR CASE, OR REPLACEMENT OF ENTIRE VSV TORQUE SHAFT SHALL BE REQUIRED.

c.

(3)

Using nylon sling and overhead hoist, lift VSV torque shaft (8) onto HPC stator case.

(4)

Align forward and aft mounting brackets (7 and 9) on HPC stator case mounting bosses.

(5)

Apply thread lubricant to threads of mounting bolts (1).

(6)

Using four bolts (1), secure forward mounting bracket (7) to HPC stator case. Tighten bolts finger-tight.

(7)

Using four bolts (1), secure aft mounting bracket (9) to HPC stator case. Tighten bolts finger-tight.

Connect eight input rods (5) to connecting links (6) as follows: NOTE IGV input rod connection is in opposite direction of other VSV stages. (1)

Align forward most input rod (5) with IGV connecting link (6). Install bolt (2), flat washer (3), and nut (4). Tighten bolt finger-tight.

(2)

Align remaining input rods (5) with appropriate connecting links (6). Install bolt (2), flat washer (3), and nut (4). Tighten bolts finger-tight.

d.

Tighten bolts (1) to 204-226 lb in. (23.1-25.5 N⋅m) of torque and safety wire.

e.


f.

Install VSV actuator (10) per WP 100 00.




WORK PACKAGE

TECHNICAL PROCEDURES FUEL PUMP REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 11 ................. 0 12 Blank............ 0 Alphabetical Index Page

Subject Fuel Pump Installation. ...................................................................................................... Fuel Pump Removal. ...........................................................................................................

7 3


GEK 105054 Volume II WP 115 00 1.


Introduction. This work package provides instructions for removing and installing the optional fuel pump from the accessory gearbox (ABG) or off-engine motor drive.

2.


Number


GEK 105054 WP 002 00 GEK 105055

3.


4.



Lubricating Oil




IPB Figure No./Item

Gasket Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing Seal

6-10 TBP TBP TBP TBP TBP TBP TBP TBP TBP




Fuel Pump Removal. a.


b.

c.

d.

•


•


Drain fuel from fuel pump (1) as follows: (1)

Remove safety wire and remove drain plug (25, figure 1). Remove and discard preformed packing (26).

(2)

Drain fuel into approved waste container.

Remove fuel pump adapter (3) as follows: (1)

Remove six nuts (6) and washers (5) that secure fuel pump adapter (3) to fuel pump (1).

(2)

Remove two preformed packings (4) from fuel pump adapter (3). Discard preformed packings.

Disconnect pilot pressure hose (18) from fuel pump (1) as follows: (1)

Disconnect pilot pressure hose (18) from tube nipple (19).

(2)

Remove tube nipple (19) and preformed packing (20) from fuel pump (1). Discard preformed packing.

e.

Remove fuel supply hose (17) per packager’s manual.

f.

If required, remove safety wire and remove plug (21) from boost discharge pressure port. Remove and discard preformed packing (22). WARNING

g.

•


•


If required, remove safety wire and remove plug (23) from filter outlet port. Remove and discard preformed packing (22). 3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Fuel Pump (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Fuel Pump (Sheet 2 of 2)




h.

Remove bypass fuel hose (24) per packager’s manual.

i.

Remove fuel discharge hose (27) as follows: (1)

Disconnect fuel discharge hose (27) from tube nipple (29).

(2)

Remove tube nipple (29) and preformed packing (28) from fuel pump (1). Discard preformed packing.

j.

If replacing fuel pump (1), remove cover plate (31) from fuel pump by removing six self-locking nuts (36) and washers (35).

k.

If replacing fuel pump (1), remove fuel filter assembly as follows:

l.

(1)

Remove drain plug (37) from fuel filter assembly. Drain fuel into a suitable container. Remove and discard preformed packing (38).

(2)

Using strap wrench, remove filter bowl (39). Remove and discard preformed packing (45).

(3)

Remove and discard filter element (41) and preformed packings (40).

(4)

Remove four bolts (34) and washers (33) that secure filter head (43) and attaching parts to fuel pump (1). Remove two self-locking nuts (48) and washers (47) from studs (46). Remove and discard gasket (42).

Remove fuel pump (1) from AGB or drive motor as follows: (1)

Remove safety wire and remove bolt (14) from outer ring (10).

(2)

Remove ball seat washer (15) and packing with retainer (16) from bolt (14). Discard packing with retainer. CAUTION

SUPPORT FUEL PUMP DURING REMOVAL OF OUTER RING TO AVOID DROPPING FUEL PUMP OR DAMAGING SPLINED DRIVE SHAFT.

k.

(3)

Using plastic mallet, strike lug at bottom of outer ring (10) to drive outer ring in counterclockwise (CCW) direction, aft looking forward (ALF).

(4)

Rotate outer ring (10) in CCW direction, ALF, until outer ring rotation stops.

(5)

Pull fuel pump (1) straight aft from AGB, until splined drive shaft (30) disengages from AGB fuel pump gearshaft.

(6)

Remove and discard preformed packing (2) from splined drive shaft (30).

(7)

Remove seal (9) from outer ring (10). Discard seal.

Cover or cap all open ports in fuel pump (1).




Fuel Pump Installation. NOTE If AGB has never had fuel pump installed, proceed as follows. If AGB has had fuel pump previously installed, proceed to step b. a.

Prepare AGB fuel pump gearshaft (5, figure 2) as follows: NOTE Fuel pump mounting pad on AGB is located on aft left side, ALF, of AGB. (1)

Remove safety wire and eight bolts from cover on AGB fuel pump mounting pad. Remove and discard gasket.

(2)

Remove AGB gearshaft seal from inside diameter (ID) of AGB fuel pump gearshaft (5) as follows: (a) Using 1/4 inch open end wrench, hold end of tie rod (1) on flats provided. (b) Remove nut (8) from tie rod (1). (c) Shake tie rod (1) until clevis (6) disengages from behind splines in AGB fuel pump gearshaft (5). (d) Pull seal assembly from ID of AGB fuel pump gearshaft (5). (e) Remove two preformed packings (2 and 3) from seal assembly.

(3)

Install gasket (8, figure 1) on adapter (7).

(4)

Using eight screws (11), install adapter (7) onto AGB fuel pump pad. Tighten screws to 190-230 lb in. (21.5-25.9 N⋅m) of torque.

(5)

Using two bolts (13), secure ball socket bracket (12) to adapter (7). Torque bolts to 190-230 lb in. (21.5-25.9 N⋅m) of torque.

(6)

Install outer ring (10) onto adapter (7) by aligning arrow on outer ring with ball socket bracket (12).

(7)

Rotate outer ring 180 degrees clockwise (CW), ALF, until remaining arrow on outer ring aligns with ball socket bracket (12). NOTE

Ensure seal tangs are installed facing forward and snap over AGB counterbore ID. b.

Install seal (9) onto outer ring (10). 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. AGB Fuel Pump Gearshaft Seal WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. c.

Using lubricating oil, lightly coat preformed packing (2) and install onto splined drive shaft (30).

d.

Using lubricating oil, lightly coat splined drive shaft (30).

e.

Install fuel pump (1) onto AGB as follows: (1)

Rotate outer ring (10) in CCW direction, ALF, until it stops.

(2)

Align splined drive shaft (30) with mating spline.

(3)

Align fuel pump locating pins with AGB mating holes.

(4)

Insert fuel pump (1) into outer ring (10).

(5)

Rotate outer ring (10) in CW direction, ALF, until locking tabs on outer ring engage locking tabs on fuel pump (1) mounting flange.



g.


Secure outer ring (10) in place as follows: (1)

Install ball seat washer (15) onto bolt (14).

(2)

Install bolt (14) into ball socket bracket (12).

(3)

Install packing with retainer (16) onto bolt (14) so it will be located between ball socket bracket (12) and outer ring (10) lug.

(4)

Install bolt (14) into outer ring (10) lug. Tighten bolt to 190-230 lb in. (21.5-25.9 N⋅m) of torque.

(5)

After tightening bolt (14), safety-wire two bolts (13) and bolt (14) together.

Connect hoses to fuel pump (1) as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Using lubricating oil, lightly coat preformed packing (20) and install packing onto tube nipple (19).

(2)

Install tube nipple (19) into fuel pump (1). Tighten tube nipple to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

(3)

Using lubricating oil, lightly coat preformed packing (28) and install packing onto tube nipple (29).

(4)

Install tube nipple (29) into fuel pump (1). Tighten to 58-70 lb ft (78.7-94.9 N⋅m) of torque.

(5)

Using lubricating oil, lightly coat preformed packing (22) and install packing onto plug (21).

(6)

Install plug (21) into boost discharge pressure port of fuel pump (1). Tighten plug to 135-155 lb in. (15.3-17.5 N⋅m) of torque. WARNING


Using lubricating oil, lightly coat preformed packing (26) and install packing onto drain plug (25). 9




(8)

Install drain plug (25) into fuel pump (1). Tighten drain plug to 270-300 lb in. (30.5-33.9 N⋅m) of torque.

(9)

Using lubricating oil, lightly coat two preformed packings (4) and install packings into fuel pump adapter (3).

(10) Using six nuts (6) and washers (5), secure fuel pump adapter (3) onto fuel pump (1). Tighten nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque. (11) Using six washers (35) and self-locking nuts (36) install cover plate (31) to fuel pump (1). Tighten nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque. (12) Secure fuel bypass hose (24) onto fuel pump (1) per packager’s manual. (13) Using lubricating oil, lightly coat preformed packing (22) and install packing onto plug (23). Install plug (23) into filter outlet pressure port of fuel pump (1). Tighten plug (23) to 135-155 lb in. (15.3-17.5 N⋅m) of torque. (14) Install pilot pressure hose (18) onto tube nipple (19). Tighten B-nut as follows: (a) Tighten B-nut to 135-155 lb in. (15.3-17.5 N⋅m) of torque. (b) Loosen until B-nut is free running and retighten to 135-155 lb in. (15.3-17.5 N⋅m) of torque at each joint. (c) Check B-nut by reapplying 135-155 lb in. (15.3-17.5 N⋅m) of torque. (15) Install fuel discharge hose (27) onto tube nipple (29). Tighten B-nut as follows: (a) Tighten B-nut to 58-70 lb ft (78.6-94.9 N⋅m) of torque. (b) Loosen until B-nut is free running and retighten to 58-70 lb ft (78.6-94.9 N⋅m) of torque at each joint. (c) Check B-nut by reapplying 58-70 lb ft (78.6-94.9 N⋅m) of torque at each joint. (16) Secure fuel supply hose (17) onto fuel pump (1) per packager’s manual. h.

Install fuel filter assembly as follows: (1)

Align gasket (42) holes with studs (46) on filter head (43). Install gasket onto fuel filter head flange.

(2)

Align studs (46) with bottom holes in fuel pump (1) flange.

(3)

Install fuel filter assembly onto fuel pump (1).




(4)

Install two washers (47) and self-locking nuts (48) onto studs (46). Tighten self-locking nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque.

(5)

Install four bolts (34) and washers (33), washers under boltheads, through fuel filter head flange. Tighten bolts to 100-130 lb in. (11.3-14.6 N⋅m) of torque.

(6)

Lubricate two preformed packings (40) with petrolatum and install a packing at either end of filter element (41). Seat filter element inside filter bowl (39).

(7)

Lubricate preformed packing (45) with petrolatum and install packing inside filter head (43).

(8)

Install filter bowl (39) onto filter head (43) hand-tight.

(9)

Lubricate preformed packing (38) with petrolatum and install onto drain plug (37).

(10) Install drain plug (37) into filter bowl (39) and tighten plug to 40-65 lb in. (4.5-7.3 N⋅m) of torque. WARNING FUEL IN LIQUID, VAPOR, OR MIST FORM IS FLAMMABLE, IRRITATING TO THE SKIN AND RESPIRATORY TRACT, AND POISONOUS IN THE DIGESTIVE TRACT. REMOVE SATURATED CLOTHING, WASH SKIN WELL, DON'T SWALLOW LIQUID, AND DON'T BREATHE MIST OR VAPOR. i.

Restore power, fuel supply, and lubricating oil supply to engine per packager’s manual. Leak-check per packager’s manual.




WORK PACKAGE

TECHNICAL PROCEDURES AIR/OIL SEPARATOR REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

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1 - 11 ................. 0 12 Blank ........... 0 Alphabetical Index Page

Subject Air/Oil Separator Installation. ........................................................................................... Air/Oil Separator Removal..................................................................................................

7 3


GEK 105054 Volume II WP 116 00 1.


Introduction. This work package contains instructions for removal and installation of the air/oil separator.

2.

3.

4.


Number


GEK 105054 WP 002 00 GEK 105055


Part No.

Tool Set, Jackscrew - Disassemble Flanges Adapter, Splined - TGB, Borescope Inspection Motor, Drive - Gas Generator Inspection Puller, Bearing Liner - Transfer Gearbox

1C6804G04 1C8033G01 1C8067G01 9441M27G01


Specification

Barrier Material Lubricating Oil

MIL-B-121 MIL-L-23699 or MIL-L-7808 Fed Spec VV-P-236 736L680G01 R297P04 (Alt)

Petrolatum Safety Cable Safety Wire 5.



Gasket Gasket Gasket Keywasher Preformed Packing Preformed Packing Gasket

49-14 59-74 56-56 8-177 8-179 55-78 59-53




Air/Oil Separator Removal. a.


b.

Disconnect V-band clamp (16, figure 1 or 2) at air/oil separator discharge port.

c.

Disconnect discharge tube (5) (refer to packager’s manual) and move tube out of way.

d.

On gas generators (Models GK and GV), or gas turbines (Model PV), with two stage power turbine, remove four bolts (20, figure 1) and disconnect air/oil separator scavenge manifold tube (7) from air/oil separator assembly (22). Remove and discard gasket (8). Remove safety wire and loosen coupling (9) at accessory gearbox (21), and rotate manifold tube down and out of way.

e.

On gas turbine (Model PK), remove bolt that secures clamp (9, figure 2) to bracket on accessory gearbox (21). Remove safety wire and remove eight bolts (20) that secure air/oil separator scavenge manifold tube (7) to air/oil separator assembly (22) and lube and scavenge pump. Remove and discard two gaskets (8).

f.

Remove six bolts and washers (4 and 6), and disconnect sump vent tube (1, figure 1 or 2) from air/oil separator assembly (22). Rotate sump vent tube out of way. Remove and discard gasket (2).

g.

Disconnect seal pressurizing tube (3) from tube nipple (14).

h.

Remove tube nipple (14) from air/oil separator assembly (22). Remove and discard preformed packing (15). Retain tube nipple

i.

Disconnect lube supply hose (25) from swivel tee fitting (26) located at check valve (27). Move hose aside.

j.

Remove angle brackets (1 and 2, figure 3, view A) from air/oil separator adapter flange by removing safety wire and three bolts (4 and 5).

k.

Remove bracket (3) from adapter flange by removing safety wire and bolt (6).

l.

Remove safety wire and loosen remaining eight bolts (17) holding adapter (13) to accessory gearbox (21). Remove all bolts and washers (17 and 18) except top two bolts.




Figure 1. Air/Oil Separator Removal/Installation-Gas Generator (Models GK, GV, and PV) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. Air/Oil Separator Removal/Installation-Gas Turbine (Model PK) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. Air/Oil Separator Adapter Flange Bracket Locations m. Install three jackscrews, 1C6804, into adapter (13) flange jackscrew holes and remove top two bolts and washers (17 and 18). NOTE Roller bearing (12) shall remain on air/oil separator impeller shaft. n.

Hold air/oil separator assembly (22) securely by hand and carefully remove air/oil separator by turning jackscrews alternately in small, equal amounts. When adapter (13) rabbet is disengaged, pull air/oil separator assembly straight out, to avoid damage to gear teeth.

o.

Remove and discard adapter preformed packing (11).

p.

Bend keywasher (23, figure 1, view A) tabs back from heads of three bolts (24). Remove three bolts (24) and keywashers (23) that secure bearing housing and outer race (10) to accessory gearbox (21).



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE If fit between bearing housing and outer race (10) is tight, it may be necessary to use bearing puller, 9441M27. q.

Remove bearing housing and outer race (10) from accessory gearbox (21). Discard keywashers (23, figure 1,view A). CAUTION ROLLER BEARING, BEARING HOUSING, AND OUTER RACE ARE MATCHED ASSEMBLIES AND HAVE SAME SERIAL NUMBER. FAILURE TO INSTALL MATCHED BEARING ASSEMBLY MAY CAUSE EXCESSIVE BEARING WEAR, RESULTING IN DAMAGE TO ACCESSORY GEARBOX ASSEMBLY.

7.

r.

Bag and tag bearing housing and outer race (10, figure 1 or 2) and attach bag to air/oil separator assembly (22).

s.

Wrap protective covering around roller bearing (12) on impeller shaft.

Air/Oil Separator Installation. CAUTION ROLLER BEARING, BEARING HOUSING, AND OUTER RACE ARE MATCHED ASSEMBLIES AND HAVE SAME SERIAL NUMBER. FAILURE TO INSTALL MATCHED BEARING ASSEMBLY MAY CAUSE EXCESSIVE BEARING WEAR, RESULTING IN DAMAGE TO ACCESSORY GEARBOX ASSEMBLY. a.

Ensure bearing housing and outer race (10, figure 1 or 2) has same serial number as roller bearing (12). WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Lubricate outer race of bearing housing and outer race (10) with clean lubricating oil.




Use nylon drift and lightweight hammer to tap bearing housing into place, if necessary. c.

Place bearing housing and outer race (10) into accessory gearbox (21) boss. Carefully align boltholes and push bearing housing into seated position. Ensure bearing housing is straight and seated.

d.

Install three new keywashers (23, figure 1, view A), prebent tab aft, and rotate counterclockwise against edge of retainer. Do not force or distort prebent tab into position. Install three bolts (24) and tighten to 33-37 lb in. (3.8-4.1 N⋅m) of torque. NOTE An overtorque to 40 lb in. (4.5 N⋅m) is permitted to position bolthead flat onto tab on keywasher.

e.

Ensure bolthead flat is aligned to keywasher tab. Bend one tab of each keywasher against bolthead flat. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

f.

Using lubricating oil, lubricate preformed packing (11, figure 1 or 2) and install into groove in adapter (13). Small amounts of petrolatum may be used to hold preformed packing in place. Ensure preformed packing is firmly seated in groove.

g.

Lubricate roller bearing (12) on gearshaft with clean, soft, white petrolatum. CAUTION GEAR TEETH ON AIR/OIL SEPARATOR SHALL MESH WITH GEAR TEETH IN ACCESSORY GEARBOX, TO PREVENT DAMAGE. ROTATION OF AIR/OIL SEPARATOR IMPELLER MAY BE NECESSARY TO ALIGN GEAR TEETH. NOTE Adapter flange has off-set bolthole, to ensure proper positioning of air/oil separator.

h.

Carefully position air/oil separator assembly (22) onto accessory gearbox (21). Ensure bearing, gears, and boltholes are aligned. Rotate air/oil separator impeller by hand as impeller gearshaft is being inserted into accessory gearbox, to ensure gear teeth mesh.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE Adapter flange has off-set bolthole, to ensure proper positioning of air/oil separator. h.

Carefully position air/oil separator assembly (22) onto accessory gearbox (21). Ensure bearing, gears, and boltholes are aligned. Rotate air/oil separator impeller by hand as impeller gearshaft is being inserted into accessory gearbox, to ensure gear teeth mesh.

i.

Install three brackets to adapter flange of air/oil separator as follows: (1)

Position upper angle bracket (1, figure 3), lower angle bracket (2) and bracket (3) on adapter flange as shown in view A. Secure brackets (1 and 2) to flange using two bolts (4) and bolt (5). Secure bracket (3) to flange using bolt (6).

(2)

Tighten bolts (4, 5, and 6) to 55-70 lb in. (6.2-7.9 N⋅m) of torque and safety-wire.

j.

Install eight remaining bolts (17, figure 1 or 2), with washers (18) under boltheads, through adapter (13) flange and finger-tighten.

k.

Remove nuts and washers and remove access cover from accessory gearbox manual drive pad located on aft side of accessory gearbox (21) between starter and lube/scavenge pump. Remove and discard preformed packing from access cover.

l.

Insert 3.0 inch (76.2 mm) long, 3/4-inch square drive extension and splined adapter, 1C8033, into accessory gearbox drive. Using ratchet wrench, slowly rotate gear train. Look for rotation of air/oil separator impeller.

m. For gas generators with optional hydraulic pump installed on manual drive pad, motor drive, 1C8067, may be used in lieu of splined adapter, 1C8033 as follows: (1)

Prior to installing motor drive, 1C8067, remove rear shaft seal assembly.

(2)

Motor drive, 1C8067, attaches to accessory drive pad located on left aft side of accessory gearbox.




DURING SEATING OF AIR/OIL SEPARATOR, ENSURE GEARS MESH. FAILURE TO PROPERLY ENGAGE GEARS, MAY RESULT IN EXTENSIVE DAMAGE TO ACCESSORY GEARBOX. n.

Using crisscross tightening pattern, seat air/oil separator assembly (22) while slowly rotating accessory gearbox gear train. Gear train shall turn freely without hang-up. CAUTION ENSURE ADAPTER IS FIRMLY AND SQUARELY SEATED IN ACCESSORY GEARBOX FLANGE AS FINAL TORQUE IS APPLIED, OR DAMAGE TO GEARS, BEARINGS, OR SEALS MAY RESULT.

o.

Using feeler (shim) stock, ensure adapter (13) is seated.

p.

Using crisscross pattern, tighten air/oil separator adapter bolts (17) to 55-70 lb in. (6.2-7.9 N⋅m) of torque. Safety-wire bolts.

q.

If motor drive, 1C8067, was used in lieu of splined adapter, 1C8033, remove motor drive, 1C8067, and reinstall rear shaft seal assembly. Replace preformed packings on rear shaft seal assembly prior to installation into gearshaft. Tighten nut on rear shaft seal assembly to 190-230 lb in. (21.5-25.9 N⋅m) of torque. Install new gasket and cover plate and tighten bolts to 190-230 lb in. (21.5-25.9 N⋅m) of torque. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7898, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

r.

Remove splined adapter, 1C8033. Using lubricating oil, lubricate preformed packing. Install preformed packing, access cover, washers and nuts, and tighten nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque.

s.

Using lubricating oil, lubricate preformed packing (15) and install onto tube nipple (14). Install tube nipple into air/oil separator assembly (22) and tighten to 450-550 lb in. (50.9-62.1 N⋅m) of torque.

t.

Connect seal pressurizing tube (3) to tube nipple (14). Tighten coupling nut to 450-550 lb in. (50.9-62.1 N⋅m) of torque.




u.

Rotate sump vent tube (1) to mate with air/oil separator assembly (22). Install gasket (2) and connect tube with six bolts (4) and washers (6). Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque and safety-wire in pairs.

v.

On gas generators (Models GK and GV), or gas turbines (Model PV) with two stage power turbine, install gasket (8, figure 1) and attach air/oil separator scavenge manifold tube (7) to air/oil separator assembly (22) with four bolts (20). Tighten bolts to 33-37 lb in. (3.8-4.1 N⋅m) of torque and safety-wire in pairs. Tighten coupling (9) at accessory gearbox end of tube to 100-110 lb in. (11.3-12.4 N⋅m) of torque and safety-wire.

w.

On gas turbines (Model PK), install gaskets (8, figure 2) and attach air/oil separator scavenge manifold tube (7) to air/oil separator assembly (22) and lube and scavenge pump, with eight bolts (20). Tighten bolts to 33-37 lb in. (3.8-4.1 N⋅m) of torque and safety-wire in pairs.

x.

Connect lube supply hose (25, figure 1 or 2) to swivel tee (26) located at check valve (27) and tighten hose to 112-128 lb ft (151.9-173.5 N⋅m) of torque.

y.

Install air discharge tube (5) per packager’s manual.





TECHNICAL PROCEDURES AIR/OIL SEPARATOR COVER REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

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Subject Air/Oil Separator Cover Installation.................................................................................. Air/Oil Separator Cover Removal.......................................................................................

6 3




Introduction.

This work package contains instructions for removal and installation of the air/oil separator cover. 2.

3.

4.

5.


Number


GEK 105054 WP 002 00 GEK 105055


Part No.

Tool Set, Transfer Gearbox Air/Oil Separator Cover Puller Heat Gun Soft-Faced Mallet

1C6842G01 9407M45 Local Purchase Local Purchase


Specification

Dry Ice Petrolatum

BB-C-104 Fed Spec VV-P-236

xpendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). Nomenclature


Preformed Packing Preformed Packing

7-7 55-78




Air/Oil Separator Cover Removal. a.


b.

Remove the air/oil separator cover from the air/oil separator housing as follows. Refer to figure 1. WARNING LUBRICATING OIL, MIL-L-23699, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Put a suitable container under the air/oil separator housing (2).

(2)

Disconnect the V-band clamp (9) at the air/oil separator cover (1) discharge port.

(3)

Disconnect the discharge tube (10) per packager’s manual and move the tube out of the way.

(4)

Remove the bolt (3) and nut (4) at the seal pressurizing tube (5) clamp.

(5)

Disconnect the coupling nut (6) at the pressurizing port on the air/oil separator cover (1) and seal pressurizing tube (5).

(6)

Remove the union (7) from the pressurizing port. Remove and discard the preformed packing (8).

(7)

Remove the bolt (11) and washer (12) that attach the transfer gearbox (TGB) scavenge oil hose (13) bracket to the air/oil separator cover (1). Move the TGB scavenge oil hose out of the way of the air/oil separator cover.

(8)

Remove the remaining bolts (11) and washers (12) that attach the air/oil separator cover (1) to the air/oil separator housing (2).

(9)

Install the air/oil separator cover puller, 9407M45, from the transfer gearbox tool set, 1C6842, onto the air/oil separator cover flange. Refer to figure 2. Loosen the air/oil separator cover. Slight, careful prying may be necessary. Remove the air/oil separator cover.

(10) Remove the air/oil separator cover puller from the air/oil separator cover. (11) Remove and discard the preformed packing from the air/oil separator cover.




Figure 1. Air/Oil Separator Removal/Installation 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. Air/Oil Separator Cover Puller, 9407M45




Air/Oil Separator Cover Installation. a.

Install the air/oil separator cover on the air/oil separator housing as follows. Refer to figure 1. (1)

Using dry ice, BB-C-104, chill the air/oil separator cover (1).

(2)

Using a heat gun, heat the air/oil separator housing (2).

(3)

Lubricate a preformed packing and the mating surfaces of the air/oil separator housing (2) and air/oil separator cover (1) with soft petrolatum, VV-P-236. Install the preformed packing into the groove on the air/oil separator cover.

(4)

Put the air/oil separator cover (1) on the air/oil separator housing (2) with the pressurizing port located at the 12:30 o’clock position, forward looking aft. Use a soft-faced mallet to lightly tap the air/oil separator cover into position. CAUTION

DO NOT ATTEMPT TO DRAW AIR/OIL SEPARATOR COVER TO SEATED POSITION WITH BOLTS. DO NOT STRIKE AIR/OIL SEPARATOR COVER ON FLANGE. (5)

Attach the TGB scavenge oil hose (13) clamp to the air/oil separator cover (1) with a bolt (11) and washer (12). Install the remaining bolts (11) and washers (12). Continue to lightly tap the air/oil separator cover and tighten the bolts until seated.

(6)

Tighten the bolts (11) to a torque of 33-37 lb in. (3.7-4.2 N⋅m) and safetywire.

(7)

Lubricate a preformed packing (8) with soft petrolatum, VV-P-236, and install it on the union (7). Install the union into the pressurizing port, and tighten to 270-300 lb in. (30.5-33.9 N⋅m) of torque.

(8)

Connect the seal pressurizing tube (5) at the union (7). Tighten the coupling nut (6) to 450-550 lb in. (50.8-62.1 N⋅m) of torque.

(9)

Install a bolt (3) and nut (4) at the seal pressurizing tube (5) clamp. Tighten the bolt to 33-37 lb in. (3.7-4.2 N⋅m) of torque.

(10) Install the discharge tube (10) onto the air/oil separator cover (1) discharge port per packager’s manual. Tighten the V-band clamp (9) to 45-55 lb in. (5.1-6.2 N⋅m) of torque.




WORK PACKAGE

TECHNICAL PROCEDURES PNEUMATIC STARTER (SHROUDED/NONSHROUDED) REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Pneumatic Starter Installation. ......................................................................................... Pneumatic Starter Removal. ..............................................................................................

6 3


GEK 105054 Volume II WP 117 00 1.


Introduction. This work package contains instructions for removal and installation of shrouded and nonshrouded pneumatic starters from the accessory gearbox.

2.


Number


GEK 105054 WP 002 00 GEK 105055

3.


4.


Specification

Lubricating Oil





Gasket Metal Gasket Preformed Packing Preformed Packing Preformed Packing Preformed Packing

76-2 TBP 76-3 76-5 76-14 76-18




Pneumatic Starter Removal. a.

Comply with all instructions contained in WP 002 00. CAUTION ENSURE AIR OR GAS SUPPLY IS SHUT OFF BEFORE DISCONNECTING AIR INLET HOSE, TO PREVENT DAMAGE TO STARTER OR INJURY. NOTE Pneumatic starter can be either shrouded or nonshrouded model. See figure 1, sheet 1, for nonshrouded configuration or figure 1, sheet 2, for shrouded configuration.

b.

Disconnect inlet air tube and move clear of pneumatic starter (11, figure 1, sheet 1 or 2). Refer to packager’s manual.

c.

If applicable, remove safety wire and disconnect flexible electrical lead connector from starter (11) speed switch located at starter 7:00 o'clock position. Position flexible electrical lead end out of way. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

d.

Place suitable container under starter (11). Remove safety wire and oil drain plug (1) with metal gasket (2) located at starter 6:00 o'clock position (see detail B). Allow starter to completely drain. Discard drained oil. Inspect and replace metal gasket, if damaged. Install oil drain plug with metal gasket into starter oil drain port. Tighten drain plug to 135-155 lb in. (15.3-17.5 N⋅m) of torque and safety-wire.

e.

Disconnect oil scavenge tube assembly (14) from nipple (17) at starter lube scavenge port. Remove nut (12) and bolt (15). Retain loop clamp (16) on oil scavenge tube assembly. Disconnect oil scavenge tube assembly from screen assembly (29). Remove screen assembly. Remove and discard preformed packing (28). Cap and plug openings. Inspect and clean screen assembly.




Figure 1. Pneumatic Starter Removal/Installation (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Pneumatic Starter Removal/Installation (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



f.

Remove nipple (17) from starter lube scavenge port. Discard preformed packing (18). Install suitable shipping plug.

g.

Disconnect oil supply tube assembly (19) from elbow (27) at starter lube supply port. Remove bolt (20) and retain loop clamp (21) on oil supply tube assembly. Cap and plug openings.

h.

Loosen jamnut (26) and remove elbow (27) from starter lube supply port. Remove and discard preformed packing (22). Install suitable shipping plug.

i.

Disconnect pressurization air supply hose assembly (8) from elbow (25) at starter air supply port. Remove nut (7) and bolt (4). Retain loop clamps (5 and 6) on their respective hose assembly. Cap and plug openings.

j.

Loosen jamnut (24) and remove elbow (25) from starter air supply port. Discard preformed packing (23). Install suitable shipping plug. CAUTION STARTER WEIGHS APPROXIMATELY 50 LBS (22.7 KG). PROPERLY SUPPORT STARTER WHILE REMOVING, TO PREVENT DROPPING WITH SUBSEQUENT DAMAGE TO STARTER AND/OR DRIVE SPLINE.

7.

k.

Remove 12 mounting flange self-locking nuts (10) that secure starter (11) to accessory gearbox (30). Remove starter and bracket (13). Inspect gasket (9) and replace, if required. Discard drive spline preformed packing (3, detail B).

l.

Tag and identify starter (11).

Pneumatic Starter Installation. NOTE Pneumatic starter can be either shrouded or nonshrouded model. See figure 1 for nonshrouded configuration or for shrouded configuration. a.

Remove protective cover from replacement starter (11, figure 1) drive spline.

b.

If necessary, reinstall oil drain plug (1) with metal gasket (2). Tighten to 135-155 lb in. (15.3-17.5 N⋅m) of torque and safety-wire, as required.

c.

Install gasket (9) over starter mounting studs of accessory gearbox (30).




WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. d.

Lightly coat preformed packing (3) with lubricating oil. Install onto starter drive spline. CAUTION STARTER WEIGHS APPROXIMATELY 50 LBS (22.7 KG). PROPERLY SUPPORT STARTER WHILE INSTALLING, TO PREVENT DROPPING WITH SUBSEQUENT DAMAGE TO STARTER AND/OR DRIVE SPLINE.

e.

Mount starter (11) onto accessory gearbox (30) mounting studs. Starter shall be oriented to position oil drain plug (1) in down (6:00 o'clock) position. Locate bracket (13) over studs. Secure starter with 12 self-locking nuts (10). Tighten self-locking nuts to 190-230 lb in. (21.5-25.9 N⋅m) above run-on torque.

f.

Remove protective caps from elbows (25 and 27) and nipple (17). Remove protective plugs from air supply hose assembly (8), oil supply tube assembly (19), and oil scavenge tube assembly (14).

g.

Lightly coat preformed packing (18) with lubricating oil. Install preformed packing (18) onto nipple (17) and install into starter lube scavenge port. Tighten nipple to 270-300 lb in. (30.6-33.8 N⋅m) of torque. Place suitable protective cap onto nipple outer end.

h.

Lightly coat preformed packing (22) with lubricating oil. Install elbow (27), jamnut (26), and preformed packing (22) into starter lube supply port. Do not torque jamnut at this time. Install suitable protective cap onto outer end of elbow. CAUTION DO NOT INTERMIX MIL-L-23699 OIL WITH MIL-L-7808 OIL.

i.

Prelubricate starter (11) by adding 11.9-15.2 fl oz (352-449 cc) of lubricating oil, used in gas generator lubrication system, to starter sump through air supply port. Excess oil will drain from oil scavenge port.

j.

Lightly coat preformed packing (23) with lubricating oil. Install elbow (25), jamnut (24), and preformed packing (23) into starter air supply port. Do not torque jamnut at this time. Install suitable protective cap onto outer end of elbow.

k.

Align elbow (25) to proper angle to allow for proper connection of air supply hose assembly (8). Tighten jamnut (24) to 180-200 lb in. (20.4-22.5 N⋅m) of torque. 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 117 00 l.


Remove protective cap from elbow (25) and connect air supply hose assembly (8) onto elbow. Tighten hose coupling nut to 270-300 lb in. (30.6-33.8 N⋅m) of torque.

m. Align loop clamps (5 and 6) and connect using bolt (4) and nut (7). Tighten bolt to 55-70 lb in. (6.3-7.9 N⋅m) of torque. n.

Align elbow (27) to proper angle for proper connection of oil supply tube assembly (19). Tighten jamnut (26) to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

o.

Remove protective cap from elbow (27) and connect oil supply tube assembly (19) onto elbow. Tighten coupling nut to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

p.

Install loop clamp (21) and secure with bolt (20). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

q.

Remove protective cap from nipple (17) and connect oil scavenge tube assembly (14) onto nipple. Tighten coupling nut to 450-550 lb in. (50.9-62.1 N⋅m) of torque. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. NOTE Ensure screen assembly (29) is installed into the accessory gearbox (30) with the flow direction arrow pointing toward the gearbox.

r.

Lightly coat preformed packing (28) with lubricating oil. Install preformed packing (28) onto screen assembly (29). Install screen assembly (29) into accessory gearbox (30). Install oil scavenge tube assembly (14) onto screen assembly (29). Tighten coupling nut to 450-550 lb in. (50.9-62.1 N⋅m) of torque.

s.

Install loop clamp (16) onto bracket (13) and secure with bolt (15) and nut (12). Tighten bolt to 33-37 lb in. (3.8-4.1 N⋅m) of torque.

t.

If applicable, install flexible electrical lead connector to starter speed switch hand-tight and safety-wire per packager’s manual.

u.

Connect inlet air tube and outlet air tube (optional item on shrouded design) per packager’s manual. Check all torques against table 1 or packager’s manual, as applicable.

v.

Ensure removed starter (11) has proper shipping plugs, caps, and covers installed. Ensure identifying tag is attached to starter.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Pneumatic Starter Item Elbow and preformed packing Elbow and preformed packing Nipple and preformed packing Starter, gasket, and preformed packing Air supply hose assembly Screen assembly and preformed packing Oil scavenge tube assembly Oil supply tube assembly Bracket

Item No. 25, 23

To Starter air supply port

Item No. 11

With Jamnut

Item No. 24

Jamnut

26

10

Tighten 180-200 lb in. (20.4-22.5 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 270-300 lb in. (30.6-33.8 N⋅m) 190-230 lb in. (21.5-25.9 N⋅m)

27, 22

Starter lube supply port

11

17, 18

Starter lube scavenge port

11

11, 9, 3

Accessory gearbox

30

Self-locking nuts

8

Elbow

25

Coupling nut

29, 28

Accessory gearbox

30

270-300 lb in. (30.6-33.8 N⋅m) 270-300 lb in. (30.6-33.8 N⋅m)

14

29, 17

Coupling nuts

19

Screen assembly and nipple Elbow

27

Coupling nut

13

Starter

11

Self-locking nuts

10

Loop clamp

16

Bracket

13

Bolt, Nut

15, 12

Loop clamp

21

30

Bolt

20,

Oil drain plug and metal gasket Loop clamp

1, 2

Accessory gearbox Starter oil drain port

Loop clamp

6

450-550 lb in. (50.9-62.1 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 190-230 lb in. (21.5-25.9 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m) 33-37 lb in. (3.8-4.1 N⋅m) 135-155 lb in. (15.3-17.5 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m) 55-70 lb in. (6.3-7.9 N⋅m)

5

Air supply hose Air supply hose

11 8

Bolt, Nut

4, 7

8

Bolt, Nut

4, 7

Note

Safetywire




WORK PACKAGE

TECHNICAL PROCEDURES HYDRAULIC STARTER REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Hydraulic Starter Installation............................................................................................ Hydraulic Starter Removal.................................................................................................

5 3




Introduction. This work package contains instructions for removal and installation of the hydraulic starter from the accessory gearbox.

2.


Number

Operation and Maintenance Practices, Volume II General Maintenance Practices Illustrated Parts Breakdown

GEK 105054 WP 002 00 GEK 105055

3.


4.


Specification

Hydraulic Fluid

Refer to packager’s manual 736L680G01 R297P04 (Alt)


Expendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). NomenclatureI

PB Figure No. / Item

Gasket Preformed Packing Preformed Packing Preformed Packing Preformed Packing

75-3 75-2 75-5 75-7 75-15




Hydraulic Starter Removal. a.


b.

Position container under hydraulic starter (1, figure 1). WARNING

•

SERIOUS INJURY CAN OCCUR WHEN APPLYING HYDRAULIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS.

•

HYDRAULIC FLUID IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. CAUTION

ENSURE COUPLING FITTINGS ARE RESTRAINED WHEN LOOSENING COUPLING NUT. FAILURE TO COMPLY MAY RESULT IN PART DAMAGE. c.

Remove seal drain hose (18). Allow fluid to drain into plastic container. Remove union (17). Remove and discard preformed packing (16). NOTE Starters may have 0, 1, or 2 distributors.

d.

If distributor is not present, disconnect packager supplied hoses equipped with SAE flanges.

e.

If distributor is present, proceed as follows: (1)

Remove outlet hose (6). Remove safety wire from four bolts (3). Remove outlet distributor (5) by removing four bolts. Remove and discard preformed packing (4).

(2)

Remove inlet hose (9). Remove safety wire from four bolts (10). Remove inlet distributor (8) by removing four bolts (10). Remove and discard preformed packing (7).

(3)

Remove case drain hose (11). Remove tube nipple (12). Remove and discard preformed packing (13).




Figure 1. Hydraulic Starter Removal/Installation 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE Starters may have two additional hoses attached to top and bottom for recirculating system. f.

If applicable, disconnect recirculating system hoses from top and bottom of starter per packager’s manual.

g.

Plug all ports with suitable plastic plugs. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION HYDRAULIC STARTER WEIGHS APPROXIMATELY 100 LBS (45.4 KG). PROPERLY SUPPORT STARTER WHILE REMOVING TO PREVENT DAMAGE TO STARTER AND/OR DRIVE SPLINE DUE TO DROPPING.

7.

h.

Support hydraulic starter (1) and remove 12 nuts (2). Carefully move hydraulic starter aft until drive spline clears. Place hydraulic starter on suitable workbench. Remove and discard preformed packing (15). Inspect and, if necessary, replace gasket (14).

i.

Tag and identify hydraulic starter (1).

Hydraulic Starter Installation. WARNING HYDRAULIC FLUID IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. a.

Remove protective drive spline cover from hydraulic starter (1, figure 1). Drain any hydraulic fluid inside hydraulic starter into plastic container. Discard hydraulic fluid in accordance with local directives.




LUBRICATING OIL, MIL-L-23699, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. b.

Position gasket (14) onto accessory gearbox mounting studs. Lubricate preformed packing (15) and drive spline with lubricating oil. Install preformed packing onto drive spline. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION HYDRAULIC STARTER WEIGHS APPROXIMATELY 100 LBS (45.4 KG). PROPERLY SUPPORT STARTER WHILE INSTALLING TO PREVENT DAMAGE TO STARTER AND/OR DRIVE SPLINE DUE TO DROPPING.

c.

Lubricate drive spline with lubricating oil. Position hydraulic starter (1), engage drive spline, and mount hydraulic starter onto accessory gearbox mounting studs. Secure with 12 nuts (2). Tighten nuts to 190-230 lb in. (21.5-25.9 N⋅m) of torque.

d.

Remove protective plastic caps and plugs from starter. WARNING HYDRAULIC FLUID IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. CAUTION

e.

•

Ensure coupling fittings are restrained when tightening coupling nut. Failure to comply may result in part damage.

•

The preformed packings used in following steps shall be lubricated with hydraulic fluid, only. Do not use gas generator lubricating oil.

Lubricate preformed packing (16) with hydraulic fluid, and install onto tube nipple (17). Install tube nipple (17) into hydraulic starter (1). Tighten tube nipple to 135-155 lb in. (15.3-17.5 N⋅m) of torque. Install seal drain hose (18) onto tube nipple. Tighten coupling nut to 135-155 lb in. (15.3-17.5 N⋅m) of torque.




WARNING HYDRAULIC FLUID IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. f.

Lubricate preformed packing (4) with hydraulic fluid, and install into outlet distributor (5). Position outlet distributor (5) onto hydraulic starter (1) and secure with four bolts (3). Tighten bolts to 160-210 lb in. (18.1-23.7 N⋅m) of torque and safety-wire.

g.

Install outlet hose (6) onto outlet distributor (5) and secure coupling nut. Tighten coupling nut to 112-128 lb ft (151.9-173.5 N⋅m) of torque. CAUTION

•

Ensure coupling fittings are restrained when tightening coupling nut. Failure to comply may result in part damage.

• The preformed packings used in following steps shall be

lubricated with hydraulic fluid only. Do not use gas generator lubricating oil.

h.

Lubricate preformed packing (13) with hydraulic fluid and install onto tube nipple (12). Install tube nipple (12) into hydraulic starter (1) and tighten to 540-600 lb in. (61.1-67.7 N⋅m) of torque. Install case drain hose (11) onto tube nipple (12), and tighten coupling nut to 75-91 lb ft (101.7-123.4 N⋅m) of torque.

i.

Lubricate preformed packing (7) with hydraulic fluid and install into inlet distributor (8). Position inlet distributor (8) onto hydraulic starter (1) and secure with four bolts (10). Tighten bolts to 160-210 lb in. (18.1-23.7 N⋅m) of torque and safety-wire.

j.

Install inlet hose (9) onto inlet distributor (8) and secure with coupling nut. Tighten coupling nut to 112-128 lb ft (151.9-173.5 N⋅m) of torque. CAUTION ENSURE HYDRAULIC STARTER SYSTEM HAS BEEN SERVICED PER OEM OR MANUFACTURER'S INSTRUCTIONS BEFORE INITIAL START OF GAS GENERATOR IS ACCOMPLISHED.

k.

Service hydraulic starter system per OEM or manufacturer’s manual before initial start of gas generator.




WORK PACKAGE

TECHNICAL PROCEDURES ULTRAVIOLET FLAME SENSING SYSTEM COMPONENTS REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Ultraviolet Flame Sensing Components Installation........................................................ Ultraviolet Flame Sensing Components Removal.............................................................

6 3


GEK 105054 Volume II WP 118 00 1.


Introduction. This work package provides instructions for removal and installation of the ultraviolet (UV) flame sensing components from the compressor rear frame (CRF).

2.


Number


GEK 105054 WP 002 00

3.


4.


5.

Nomenclature


Thread Lubricant

GE Spec A50TF201 or MIL-T-5544





Ultraviolet Flame Sensing Components Removal. a.


b.

Remove UV flame sensor from bracket as follows:

c.

(1)

If applicable, remove UV flame sensor at 1:00 o’clock position per packager’s manual.

(2)

If applicable, remove UV flame sensor at 9:00 o’clock position per packager’s manual.

If required, remove brackets (figure 1) from CRF as follows: (1)

Remove bracket (1) at 1:00 o’clock position as follows: (a) Remove two bolts (2) and self-locking nuts (3) that secure bracket (1) to CRF mid flange. (b) Remove five bolts (4) and self-locking nuts (5) that secure bracket (1) to CRF mid flange. (c) Remove bracket (1) from CRF mid flange.

(2)

Remove bracket (1) at 9:00 o’clock position as follows: (a) Remove two bolts (4) and self-locking nuts (5) that secure bracket (1) to CRF mid flange. (b) Remove five bolts (2) and self-locking nuts (3) that secure bracket (1) to CRF mid flange. (c) Remove bracket (1) from CRF mid flange. CAUTION

USE CAUTION WHEN REMOVING SIGHT GLASS ASSEMBLY TO AVOID DAMAGING WINDOW. d.

If required, remove CRF flame sight (6) as follows: (1)

If applicable, remove safety wire and remove flame sight (6) and flat washer (7) at 1:00 o’clock position.

(2)

If applicable, remove safety wire and remove flame sight (6) and flat washer (7) at 9:00 o’clock position.




Figure 1. Flame Sensing System Components (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Flame Sensing System Components (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 118 00 7.


Ultraviolet Flame Sensing Components Installation. a.

If required, install CRF flame sight (6) as follows: CAUTION USE CAUTION WHEN INSTALLING FLAME SIGHT ASSEMBLY TO AVOID DAMAGING WINDOW. DO NOT OVERTORQUE. (1)

If applicable, install flame sight (6) and flat washer (7) at 1:00 o’clock position as follows: CAUTION

ENSURE THREAD LUBRICANT DOES NOT COVER FLAME SIGHT LENS OR IMPROPER UV FLAME SENSOR OPERATION MAY OCCUR. (a) Using thread lubricant, lubricate flame sight (6) and flat washer (7) contact faces. (b) Install flame sight (6) and flat washer (7) into CRF. (c) Tighten flame sight (6) to 140-160 lb in. (15.9-18.0 N⋅m) of torque and safety wire. (2)

If applicable, install flame sight (6) and flat washer (7) at 9:00 o’clock position as follows: CAUTION

ENSURE THREAD LUBRICANT DOES NOT COVER FLAME SIGHT LENS OR IMPROPER UV FLAME SENSOR OPERATION MAY OCCUR. (a) Using thread lubricant, lubricate flame sight (6) and flat washer (7) contact faces. (b) Install flame sight (6) and flat washer (7) into CRF. (c) Tighten flame sight (6) to 140-160 lb in. (15.9-18.0 N⋅m) of torque and safety wire. b.

Install brackets as follows: (1)

Install bracket (1) at 1:00 o’clock position as follows: (a) Using thread lubricant, coat threads and contact faces of bolts (2 and 4) and self-locking nuts (3 and 5).




(b) Position bracket (1) onto aft side of CRF mid flange. (c) Using two bolts (2) and self-locking nuts (3), secure bracket (1) to CRF mid flange. Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. (d) Using five bolts (4) and self-locking nuts (5), secure bracket (1) to CRF mid flange. Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. (2)

Install bracket (1) at 9:00 o’clock position as follows: (a) Using thread lubricant, coat threads and contact faces of bolts (2 and 4) and self-locking nuts (3 and 5). (b) Position bracket (1) onto aft side of CRF mid flange. (c) Using two bolts (4) and self-locking nuts (5), secure bracket (1) to CRF mid flange. Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. (d) Using five bolts (2) and self-locking nuts (3), secure bracket (1) to CRF mid flange. Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

c.

Install UV flame sensor onto bracket as follows: (1)

If applicable, install UV flame sensor at 1:00 o’clock position per packager’s manual.

(2)

If applicable, install UV flame sensor at 9:00 o’clock position per packager’s manual.




WORK PACKAGE

TECHNICAL PROCEDURES ACCESSORY GEARBOX CARBON SEALS REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Accessory Gearbox Carbon Seals Installation. .................................................................. Accessory Gearbox Carbon Seals Removal. .......................................................................

6 3


GEK 105054 Volume II WP 119 00 1.


Introduction. This work package contains instructions for removal and installation of accessory gearbox carbon seals.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel Pump Replacement Pneumatic Starter (Shrouded/Non Shrouded) Replacement Hydraulic Starter Replacement Hydraulic Pump Replacement Variable Stator Vane Servovalve Replacement Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 115 00


Part No.

Fixture Set- Removal, Mating Seal Pin, Guide

1C8182G01 Locally Mfg.


Specification

Lubricating Oil

MIL-L-23699 or MIL-L-7808 Fed Spec VV-P-236

Petrolatum 5.

WP 117 00 SWP 117 01 WP 120 00 WP 121 00 GEK 105055



Flanged Oil Seal Flanged Oil Seal Flanged Oil Seal Gasket Keywasher Keywasher Keywasher Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing Seal Mating Ring Seal Mating Ring Seal Mating Ring

8-66 8-74 8-112 6-10 8-68 8-76 8-111 8-65 8-73 8-77 8-86 8-113 8-122 8-78 8-87 8-121




Accessory Gearbox Carbon Seals Removal. a.


b.

Remove variable stator vane (VSV) servovalve/hydraulic pump pad carbon seal as follows: (1)

Remove VSV servovalve per WP 121 00.

(2)

Remove hydraulic pump per WP 120 00.

(3)

Remove flanged oil seal (4, figure 1) as follows: (a) Unbend keywasher (2) tabs. NOTE

Seal retainer (3) is used at starter pad only. (b) Remove three bolts (1), keywashers (2), and seal retainer (3). Discard keywashers. NOTE Some seal configurations contain three removal slots on inner face of flange midway between boltholes. If these slots are present, disregard substep (c). (c) Rotate flanged oil seal (4) by inserting pin of offset driver, component of fixture set, 1C8182, into bolthole of seal flange and tapping lightly with hammer, until seal tangs overlap housing boss. CAUTION USE CARE TO PREVENT COCKING SEAL OR DAMAGING HOUSING DURING REMOVAL. (d) Using pry bar, component of fixture set, 1C8182, apply leverage at flanged oil seal (4) flanges. Lift seal from gearbox housing bore. (e) Using seal pick, component of fixture set, 1C8182, remove and discard preformed packing (5) from gearbox housing bore. (f) Take depth reading from gearbox housing to face of mating seal ring as referance for reassembly. Reading




Figure 1. Accessory Gearbox Carbon Seal Removal/Installation 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WHEN CARBON FACE SEAL IS REPLACED, SEAL MATING RING AND PREFORMED PACKING SHALL ALSO BE REPLACED. (g) Remove seal mating ring as follows: NOTE Tool numbers 1C8182P02 through P05 are for use at starter pad. Tool numbers 1C8182P10 through P13 are for use at VSV servovalve/hydraulic pump pads. All are components of fixture set, 1C8182. 1

Turn P06 screw (4, figure 2) counterclockwise to end of travel to retract P05 or P11 pusher plate (5) to expand.

2

Slide P04 or P12 outer sleeve (3) back allowing fingers of P03 or P10 inner sleeve (2) to expand.

3

Insert tool into seal cavity until P02 or P13 plastic stop (6) contacts seal mating ring (1).

Figure 2. Fixture Set, 1C8182



c.

d.

7.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 4

Slide P04 or P12 outer sleeve (3) over P03 or P10 inner sleeve (2), closing flexible fingers over seal mating ring (1).

5

Using 0.5-inch socket and ratchet, or equivalent, turn P06 screw (4) clockwise until seal mating ring (1) is pulled free of shaft.

6

Remove tool and slide P04 or P12 outer sleeve (3) back to release seal mating ring (1).

7

Remove and discard preformed packing (7, figure 1) from seal mating ring (6).

Remove starter pad carbon seal as follows: (1)

Remove starter per WP 117 00 or SWP 117 01.

(2)

Remove seal per step b.(3).

Remove pump/accessory pad carbon seals as follows: (1)

As required, remove bolts (10), gasket (8), and cover plate (9) or fuel pump per WP 115 00.

(2)

Remove seal per step b.(3).

Accessory Gearbox Carbon Seals Installation. a.

Install VSV servovalve/hydraulic pump pad carbon seal as follows: (1)

Install seal mating ring (6, figure 1) as follows: NOTE

Tool numbers 1C8182P07 through P08 are for use at starter pad. Tool numbers 1C8182P14 and P15 are for use at VSV control pads. All are components of fixture set, 1C8182G01. (a) Lubricate new preformed packing (7) with petrolatum, and install into seal mating ring (6) packing groove.




•

TO PREVENT SEAL DAMAGE, ENSURE THAT TANGS OF SEAL MATING RING FULLY ENGAGE SLOTS OF BEARING INNER RACE. USE CAUTION TO PREVENT SEAL MATING RING SURFACE FROM BECOMING SCRATCHED OR DAMAGED.

•

CHILLING GEAR SHAFT AND HEATING SEAL MATING RING SHALL FACILITATE INSTALLATION AND HELP KEEP PREFORMED PACKING FROM ROLLING. ROLLED PACKING SHALL PREVENT SEAL MATING RING FROM SEATING.

(b) Using P07 or P14 arm and P08 or P15 yoke, install new seal mating ring (6) onto shaft so that tangs of seal mating ring fully engage slots of bearing inner race. (c) Take depth masurement of new mating ring. Compare to earlier reading to assure ring is seated. Reading (2)

Install flanged oil seal (4) as follows: (a) Lubricate preformed packing (5) with petrolatum, and install into gearbox housing bore. WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (b) Lubricate internal elements of flanged oil seal (4) with lubricating oil. Flex seal through travel range several times, to prevent excessive friction of internal components. (c) Apply light coat of lubricating oil to seal face, seal housing outside diameter, and face of seal mating ring (6). NOTE Guide pins may be locally fabricated by grinding heads off No. 10-32 bolts. (d) Install guide pins into gearbox housing inserts to align seal tang boltholes with inserts during installation.




•

PRIOR TO INSTALLATION, ENSURE SEAL IS CLEAN AND FREE OF DEBRIS, OR DAMAGE TO SEAL MAY OCCUR.

•

DURING SEAL INSTALLATION, ENSURE PREFORMED PACKING IS NOT DISTURBED OR DAMAGED. DAMAGED PACKING CAN PREVENT SEAL FROM SEALING.

(e) Install flanged oil seal (4) over guide pins and carefully push into housing until seal flange is fully seated against face of housing. Remove guide pins. (f) At starter pad, install seal retainer (3). CAUTION KEYWASHER TAB SHALL CONTACT COUNTERCLOCKWISE AGAINST TOP RETAINER OR HOUSING WITH ZERO CLEARANCE. DO NOT FORCE OR DISTORT PREBENT TAB OF KEYWASHER INTO POSITION. (g) Install keywashers (3, figure 3) and bolts (1).

Figure 3. Typical Keywasher Installation



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE Do not loosen bolt to position flat of bolthead adjacent to tab.

(h) Tighten bolts (1, figure 1) to 33-37 lb in. (3.8-4.1 N⋅m) of torque and determine if flat on bolthead is adjacent to tab of keywasher (2). If necessary, continue to tighten bolt to maximum of 40 lb in. (4.5 N⋅m) of torque, until flat of bolthead is adjacent to tab. Bend tab of keywasher against bolthole flat after applying torque.

b.

c.

(3)

Install hydraulic pump per WP 120 00.

(4)

Install VSV servovalve per WP 121 00.

Install starter pad carbon seal as follows: (1)

Install seal per steps a.(1) and (2).

(2)

Install starter per WP 117 00 or SWP 117 01.

Install pump pad carbon seal as follows: (1)

Install seal per steps a.(1) and (2).

(2)

If removed, install gasket (8) onto accessory gearbox aft left drive pad.

(3)

Install cover plate (9) and secure with bolts (10). Tighten bolts to 190-230 lb in. (21.5-25.9 N⋅m) of torque.

(4)

If removed, install fuel pump per WP 115 00.




WORK PACKAGE

TECHNICAL PROCEDURES HYDRAULIC PUMP REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Hydraulic Pump Installation.............................................................................................. Hydraulic Pump Removal. ..................................................................................................

5 3


1

GEK 105054 Volume II WP 120 00 1.


Introduction. This work package provides instructions for the removal and installation of the hydraulic pump. The hydraulic pump, variable stator vane (VSV) servovalve, and hydraulic filter housing may be removed as an assembly.

2.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Variable Stator Vane Servovalve Replacement Hydraulic Filter Housing and Element Replacement Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 121 00 WP 122 00 GEK 105055

3.


4.



Lubricating Oil

MIL-L-23699 or MIL-7808 736L680G01 R297P04 (Alt)


2


IPB Figure No./Item

Gasket Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing

55-34 55-35 55-25 55-32 55-26 55-31




Hydraulic Pump Removal. a.


b.

Remove VSV servovalve (1, figure 1) per WP 121 00.

c.

Remove hydraulic filter housing (5) per WP 122 00. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

d.

Remove hydraulic pump lube oil lines as follows: (1)

Remove lube oil supply hose from reducer fitting in hydraulic pump lube oil supply port (9). Drain residual oil into approved waste container.

(2)

Remove lube oil return hose from reducer fitting in hydraulic pump lube oil return port (8). Drain residual oil into container.

(3)

Remove reducer fitting and preformed packing from hydraulic pump lube oil supply port (9). Retain reducer fitting and discard preformed packing.

(4)

Remove reducer fitting and preformed packing from hydraulic pump lube oil return port (8). Retain reducer fitting and discard preformed packing. NOTE

Fittings can either be packager supplied nipple/reducer fittings or plugs. (5)

If applicable, remove packager supplied hoses from fittings at hydraulic pump filter in port (12), filter out port (11), and fuel metering valve port (10). Remove and discard preformed packings from fittings.

(6)

If applicable, remove plugs from hydraulic pump filter in port (12), filter out port (11), and fuel metering valve port (10). Remove and discard preformed packings from plugs.

e.

Remove safety wire and remove V-band clamp (3) that secures hydraulic pump (2) to accessory gearbox (4).

f.

Remove hydraulic pump (2) and gasket (7) from accessory gearbox (4). Inspect gasket and replace, if required. Discard drive spline preformed packing (6).

g.

Cover or cap all openings in hydraulic pump.


3



Figure 1. Hydraulic Pump Removal/Installation 4


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines h. 7.


Cover accessory gearbox hydraulic pump mounting pad, to prevent entry of debris.

Hydraulic Pump Installation. a.

Uncover or uncap hydraulic pump openings.

b.

Uncover accessory gearbox hydraulic pump mounting pad opening.

c.

Install hydraulic pump (2, figure 1) onto accessory gearbox (4) as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Lubricate drive spline preformed packing (6) with lubricating oil, and install onto drive spline.

(2)

Position gasket (7) onto hydraulic pump (2) mounting flange. CAUTION

DOWEL PIN ON HYDRAULIC PUMP MUST ENGAGE HOLE ON ACCESSORY GEARBOX. IT IS ADVISABLE TO HAVE TWO PEOPLE PERFORM HYDRAULIC PUMP INSTALLATION TO ENSURE DOWEL PIN ENGAGEMENT. IMPROPER ALIGNMENT OF THE DOWEL PIN DURING INSTALLATION CAN CAUSE DAMAGE TO THE HYDRAULIC PUMP AND ACCESSORY GEARBOX. (3)

Carefully install hydraulic pump (2) onto accessory gearbox (4). Ensure spline shaft engages correctly.

(4)

Install V-band clamp (3) onto hydraulic pump and accessory gearbox (4).

(5)

Install V-band clamp (3) as follows: (a) Tighten nut to 40 lb in. (4.5 N⋅m) of torque. (b) Ensure V-band clamp (3) is seated equally over both hydraulic pump and accessory gearbox flanges. (c) Using plastic mallet, tap circumference of V-band clamp (3) to distribute tension. (d) Tighten nut to 70-90 lb in. (8.0-10.1 N⋅m) of torque, while tapping V-band clamp (3). (e) Tap V-band clamp (3) and reapply final torque and safety wire. Change 1


5

GEK 105054 Volume II WP 120 00 d.


Install fittings into lube oil return port (8), lube oil supply port (9), fuel metering valve port (10), filter out port (11), and filter in port (12) as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Lubricate five preformed packings with lubricating oil.

(2)

Install preformed packing onto reducer fittings. NOTE


Install preformed packings onto either packager supplied nipple/reducer fittings or plugs.

(4)

Install reducer fitting into hydraulic pump lube oil supply port (9). Tighten to 45-50 lb ft (61.1-67.7 N⋅m) of torque.

(5)

Install reducer fitting into hydraulic pump lube oil return port (8). Tighten to 360-400 lb in. (40.7-45.1 N⋅m) of torque. NOTE


Install either packager supplied fittings per packager’s manual or plugs as follows: (a) Install plug into hydraulic pump filter in port (12). Tighten to 180-200 lb in. (20.3-22.6 N⋅m) of torque. (b) Install plug into hydraulic pump filter out port (11). Tighten to 180-200 lb in. (20.3-22.6 N⋅m) of torque. (c) Install plug into hydraulic pump fuel metering valve port (10). Tighten to 270-300 lb in. (30.5-33.9 N⋅m) of torque.

6




Install lube oil hoses onto lube oil return port (8), lube oil supply port (9), fuel metering valve port (10), filter out port (11), and filter in port (12) fittings as follows: CAUTION USE COUNTERTORQUE WHEN TIGHTENING FITTINGS, TO AVOID DAMAGE TO HYDRAULIC PUMP PORT THREADS. (1)

Install lube oil supply hose onto reducer fitting in hydraulic pump lube supply port (9). Tighten hose fitting to 54-64 lb ft (73.2-86.7 N⋅m) of torque.

(2)

Install lube oil return hose onto reducer fitting in hydraulic pump lube oil return port (8). Tighten hose fitting to 450-550 lb in. (50.9-62.1 N⋅m) of torque.

(3)

If applicable, install packager supplied hoses to hydraulic pump filter in port (12), filter out port (11), and fuel metering valve port (10) fittings per packager’s manual.

f.

Install hydraulic filter housing (5) onto hydraulic pump (2) per WP 122 00.

g.

Install VSV servovalve (1) onto hydraulic pump (2) per WP 121 00.


7/(8 Blank)



WORK PACKAGE

TECHNICAL PROCEDURES VARIABLE STATOR VANE SERVOVALVE REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 6 ................... 0


Page

Variable Stator Vane Servovalve Installation. .................................................................. Variable Stator Vane Servovalve Removal. .......................................................................

5 3


GEK 105054 Volume II WP 121 00 1.


Introduction. This work package provides instructions for the removal and installation of the variable stator vane servovalve. The hydraulic pump, variable stator vane (VSV) servovalve, and hydraulic filter housing may be removed as an assembly.

2.


Number


GEK 105054 WP 002 00 GEK 105055

3.


4.


5.

Nomenclature


Lubricating Oil


Expendable Material. Nomenclature

IPB Figure No./Item

Preformed Packing Preformed Packing Preformed Packing Preformed Packing

55-39 55-40 55-41 55-25




Variable Stator Vane Servovalve Removal. a.


b.

Disconnect two packager supplied electrical cables from VSV servovalve (2, figure 1) electrical connectors (1). WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

c.

d.

Disconnect VSV servovalve rod-end/head-end oil hoses as follows: (1)

Remove VSV rod-end hose from reducer fitting (8) installed in VSV servovalve rod-end port. Drain residual oil into approved waste container.

(2)

Remove VSV head-end hose from reducer fitting (7) installed in VSV servovalve head-end port. Drain residual oil into approved waste container.

(3)

Remove nipple fitting or plug (5) from accumulator port installed in VSV servovalve accumulator port. Discard preformed packing (6). Drain residual oil into approved waste container.

(4)

Remove reducer fittings (7 and 8) from rod-end and head-end ports. Discard preformed packings (4 and 6).

Remove VSV servovalve (2) as follows: CAUTION ENSURE VSV SERVOVALVE IS SUPPORTED DURING REMOVAL FROM HYDRAULIC PUMP, OR DAMAGE DUE TO DROPPING MIGHT OCCUR.

e.

(1)

Remove VSV servovalve (2) from hydraulic pump (3) by removing eight bolts (12) and eight washers (13).

(2)

Remove three preformed packings (9, 10, and 11) from VSV servovalve flange ports.

Cover all open ports with shipping or plastic covers to prevent contamination. 3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



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



Variable Stator Vane Servovalve Installation. a.

Install VSV servovalve (2) to hydraulic pump (3) as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

(1)

Lubricate three preformed packings (9, 10, and 11) with lubricating oil.

(2)

Install three preformed packings (9, 10, and 11) onto VSV servovalve flange port holes.

(3)

Align VSV servovalve (2) to hydraulic pump (3).

(4)

Install VSV servovalve (2) to hydraulic pump (3) using eight bolts (12) and eight washers (13).

(5)

Tighten bolts to 70-110 lb in. (7.9-12.4 Nxm) of torque.

Install VSV servovalve rod-end/head-end oil hoses as follows: (1)

Lubricate two preformed packings (6) and one preformed packing (4) with lubricating oil.

(2)

Install preformed packing (6) onto reducer fitting (8).

(3)

Install preformed packing (4) onto nipple fitting or plug (5).

(4)

Install preformed packing (6) onto reducer fitting (7).

(5)

Install reducer fitting (7) into VSV servovalve head-end port. Tighten to 360-400 lb in. (40.7-45.1 N⋅m) of torque.

(6)

Install reducer fitting (8) into VSV servovalve rod-end port. Tighten to 270-300 lb in. (30.6-33.8 N⋅m) of torque.

(7)

Install nipple fitting or plug (5) into VSV servovalve accumulator port. Tighten to 270-300 lb in. (30.6-33.8 N⋅m) of torque.


GEK 105054 Volume II WP 121 00 c.


Install lube oil lines onto VSV servovalve (2) as follows: (1)

Install VSV rod-end hose onto reducer fitting (8) installed in VSV servovalve rod-end port. Tighten connection to 270-300 lb in. (30.6-33.8 Nxm) of torque.

(2)

Install VSV head-end hose onto reducer fitting (7) installed in VSV servovalve head-end port. Tighten connection to 450-550 lb in. (50.9-62.1 Nxm) of torque. WARNING

ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. d.

Connect two packager supplied electrical cables to electrical connectors (1) on VSV servovalve (2) per packager’s manual.

e.

Perform functional and leak checks per packager’s manual.




WORK PACKAGE

TECHNICAL PROCEDURES HYDRAULIC FILTER HOUSING AND ELEMENT REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Hydraulic Filter Element Replacement. ............................................................................ Hydraulic Filter Housing Installation. .............................................................................. Hydraulic Filter Housing Removal. ...................................................................................

5 3 3


GEK 105054 Volume II WP 122 00 1.


Introduction. This work package contains instructions for removal and installation of the hydraulic filter housing and the hydraulic filter element.

2.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Hydraulic Pump Filter Element Inspection Illustrated Parts Breakdown


3.


4.



Isopropyl Alcohol Lint-Free Cloth Lubricating Oil

Fed Spec TT-I-735 Local Purchase MIL-L-23699 or MIL-L-7808 Local Purchase

Soft Bristle Brush 5.


IPB Figure No./Item

Gasket Hydraulic Filter Element Preformed Packing Preformed Packing

55-52 55-46 55-47 55-45




Hydraulic Filter Housing Removal. a.

Comply with all instructions contained in WP 002 00. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

7.

b.

Remove drain plug (6, figure 1) from hydraulic filter housing (4) and drain lube oil. Discard preformed packing (7).

c.

Lubricate preformed packing (7) with lubricating oil. Install onto drain plug (6).

d.

Reinstall drain plug (6) into hydraulic filter housing (4). Tighten to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

e.

Remove four bolts (1) and washers (2) that secure hydraulic filter housing (4) to hydraulic supply pump (5).

f.

Remove two self-locking nuts (9) and washers (2) from hydraulic filter mounting studs (8).

g.

Remove hydraulic filter housing (4) and gasket (3) from hydraulic supply pump (5). Inspect and replace gasket, if required.

h.

Install protective cover onto mounting flange face of hydraulic supply pump (5).

i.

Inspect hydraulic filter element per WP 408 00.

Hydraulic Filter Housing Installation. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. a.

Lubricate gasket (3) with lubricating oil.

b.

Align gasket (3) holes with mounting studs (8) on hydraulic filter housing (4). Install gasket onto hydraulic filter flange.

c.

Align hydraulic filter housing (4) mounting studs (8) with bottom holes in hydraulic supply pump (5) flange.




Figure 1. Hydraulic Filter Housing Replacement 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


8.


d.

Install hydraulic filter housing (4) onto hydraulic supply pump (5).

e.

Install two washers (2) and self-locking nuts (9) onto two hydraulic filter mounting studs (8). Tighten self-locking nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque.

f.

Install four bolts (1) and washers (2), washers under boltheads, through hydraulic filter housing (4) flange. Tighten bolts to 100-130 lb in. (11.3-14.6 N⋅m) of torque.

Hydraulic Filter Element Replacement. a.

Comply with all instructions contained in WP 002 00, if not previously done. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Remove drain plug (6, figure 2) from filter bowl (2) and drain lubricating oil. Remove and discard preformed packing (5).

c.

Lubricate preformed packing (5) with lubricating oil. Install onto drain plug (6).

d.

Reinstall drain plug (6) into filter bowl (2). Tighten plug to 135-155 lb in. (15.3-17.5 N⋅m) of torque.

e.

Using strap wrench, remove filter bowl (2) from filter head (1).

f.

Remove preformed packing (3) from filter head (1) and filter element (4) from filter bowl (2) and discard.

g.

Transfer filter bowl (2) to cleaning area. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

h.

Using isopropyl alcohol and soft bristle brush or lint-free cloth, clean filter bowl (2).




Figure 2. Hydraulic Filter Element Replacement 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG. WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS. i.

Using compressed air, dry filter bowl (2). NOTE Ensure that filter element has a preformed packing installed in each end.

j.

Seat filter element (4) into filter bowl (2). WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

k.

Lubricate preformed packing (3) with lubricating oil and install into filter head (1).

l.

Reinstall filter bowl (2) onto filter head (1) and hand-tighten.

m. Hand-tighten filter bowl (2) until bowl bottoms, approximately 50 lb ft (67.8 N⋅m) of torque maximum. n.

Using lubricating oil, refill lubricating oil supply system and pressure check hydraulic lines per packager’s manual.

o.

Motor engine per GEK 105054, Volume I, Chapter 7, and leak-check variable stator vane (VSV) system.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR DISCHARGE TEMPERATURE (T3) SENSOR REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Compressor Discharge Temperature (T3) Sensor Installation. ............... High Pressure Compressor Discharge Temperature (T3) Sensor Removal. ....................

3 3


GEK 105054 Volume II WP 123 00 1.


Introduction. This work package provides instructions for the removal and installation of two high pressure compressor (HPC) discharge temperature (T3) sensors.

2.


Number


GEK 105054 WP 002 00 GEK 105055

3.


4.


5.

Nomenclature





IPB Figure No./Item

Metal Gasket

61-3




High Pressure Compressor Discharge Temperature (T3) Sensor Removal. a.


b.

Locate T3 sensor (1 or 5, figure 1) to be removed as follows:

c.

(1)

T3 sensor (1) is located on compressor rear frame (CRF) near front flange at 12:00 o’clock position, aft looking forward (ALF).

(2)

T3 sensor (5) is located on CRF near front flange at 4:00 o’clock position, ALF.

Remove integral T3 sensor (1 or 5) electrical lead from bracket (2 or 6) as follows: WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH.

d.

7.

(1)

Remove packager cable from integral T3 sensor (1 or 5) electrical lead.

(2)

Remove safety wire and remove jamnut that secures integral T3 sensor (1 or 5) electrical lead to bracket (2 or 6).

(3)

Remove integral T3 (1 or 5) sensor electrical lead from bracket (2 or 6).

Remove T3 sensor (1 or 5) from CRF as follows: (1)

Remove safety wire from four bolts (4 or 8) used to secure T3 sensor (1 or 5) to CRF.

(2)

Remove four bolts (4 or 8) that secure T3 sensor (1 or 5) to CRF. Retain bolts.

(3)

Remove T3 sensor (1 or 5) and metal gasket (3 or 7) from CRF. Discard metal gasket.

High Pressure Compressor Discharge Temperature (T3) Sensor Installation. a.

Install T3 sensor (1 or 5, figure 1) onto CRF as follows: (1)

Install metal gasket (3 or 7) onto T3 sensor (1 or 5).

(2)

Carefully fit T3 sensor (1 or 5) into port in CRF.

(3)

Align T3 sensor (1 or 5) boltholes with boltholes in CRF boss.




Figure 1. T3 Sensor Replacement 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


b.


(4)

Coat bolt (4 or 8) threads and contact face with thread lubricant.

(5)

Using four bolts (4 or 8), secure T3 sensor (1 or 5) to CRF. Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque and safety-wire.

Install integral T3 sensor (1 or 5) electrical lead onto mounting bracket (2 or 6) as follows: (1)

Install integral T3 sensor (1 or 5) electrical lead through bracket (2 or 6).

(2)

Using jamnut, secure integral T3 sensor (1 or 5) electrical lead onto mounting bracket (2 or 6). Tighten jamnut to 25-30 lb in. (2.9-3.3 N⋅m) of torque and safety-wire. WARNING


Connect packager cable to integral T3 sensor (1 or 5) electrical lead per packager’s manual.




WORK PACKAGE

TECHNICAL PROCEDURES MAGNETIC DETECTOR PLUG REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Magnetic Detector Plug Installation. ................................................................................. Magnetic Detector Plug Removal. ......................................................................................

3 3


GEK 105054 Volume II WP 124 00 1.


Introduction. This work package covers removal and installation of magnetic detector plug located in scavenge discharge tube.

2.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Lube and Scavenge Pump Screen, Electronic Chip Detector, and Magnetic Detector Plug Inspection Illustrated Parts Breakdown


3.


4.



Isopropyl Alcohol Lint-Free Cloth Lubricating Oil

TT-I-735 Local Purchase MIL-L-23699 or MIL-L-7808 736L680G01 R297P02 (Alt)


WP 400 00 GEK 105055


IPB Figure No./Item

Preformed Packing

TBP




Magnetic Detector Plug Removal. a.


b.

Remove safety wire that secures magnetic detector plug (figure 1) to scavenge discharge tube. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

7.

c.

Remove magnetic detector plug from scavenge discharge tube. Drain residual oil into approved waste container.

d.

Remove and discard preformed packing from magnetic detector plug.

e.

Inspect magnet in plug per WP 400 00.

Magnetic Detector Plug Installation. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. a.

Using isopropyl alcohol and lint-free cloth, clean magnetic detector plug. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Lubricate new preformed packing with lubricating oil and install onto magnetic detector plug.

c.

Install magnetic detector plug into scavenge discharge tube. Tighten plug to 360-400 lb in. (40.7-45.1 N⋅m) of torque and safety-wire.

d.

Restore lubricating oil supply flow to lube and scavenge pump per packager’s manual.

e.

Motor engine per GEK 105054, Chapter 7, and check for leaks. 3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Magnetic Detector Plug Location 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES TURBINE MID FRAME REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 14.................. 1 Alphabetical Index Subject

Page

Turbine Mid Frame Installation. ....................................................................................... 10 Turbine Mid Frame Removal.............................................................................................. 4


1

GEK 105054 Volume II WP 200 00 1.


Introduction. This work package provides instructions for the removal and installation of the turbine mid frame (TMF).

2.


Title For LM2500+ Models GK and PK: Operation and Maintenance Manual, Volume I General Maintenance Practices Operation and Maintenance Manual, Volume II General Maintenance Practices Gas Generator Outside Piping and Wiring Removal and Installation Gas Turbine Outside Piping and Wiring Removal and Installation Gas Generator Miscellaneous Sump Components Replacement Gas Turbine Miscellaneous Sump Components Replacement Gas Generator Assembly Replacement Gas Generator Miscellaneous Sump Components Inspection Gas Turbine Miscellaneous Sump Components Inspection Turbine Mid Frame Inspection For LM2500+ Models GV and PV: Operation and Maintenance Manual Illustrated Parts Breakdown Operation and Maintenance Manual, Volume II General Maintenance Practices Gas Generator Outside Piping and Wiring Removal and Installation Gas Turbine Outside Piping and Wiring Removal and Installation Gas Generator Miscellaneous Sump Components Replacement Gas Turbine Miscellaneous Sump Components Replacement Gas Generator Assembly Replacement Gas Generator Miscellaneous Sump Components Inspection and Replacement Gas Turbine Miscellaneous Sump Components Inspection Turbine Mid Frame Inspection

2

GEK 105054 Chapter 10 GEK 105054 WP 002 00 WP 113 00 SWP 113 01 WP 217 00 SWP 217 01 WP 301 00 WP 413 00 SWP 413 01 WP 429 00 GEK 105052 GEK 105053 GEK 105054 WP 002 00 WP 113 00 SWP 113 01 WP 217 00 SWP 217 01 WP 301 00 WP 413 00 SWP 413 01 WP 429 00




4.


Part No.

Jackscrews, Flange Disassemble Tool Set Lift Fixture, Turbine Mid Frame

1C6804G04 1C8351G01



Isopropyl Alcohol Marking Pen

Fed Spec TT-I-735 Sharpie T.E.C. or Action Marker GE Spec A50TF142 GE Spec A50TF201 or MIL-T-5544

Petrolatum Thread Lubricant 5.



3

GEK 105054 Volume II WP 200 00 6.


Turbine Mid Frame Removal. a.


b.

Separate gas generator and power turbine as follows:

c.

(1)

Separate LM2500+ Model GK gas generator from power turbine per WP 301 00 and packager’s manual.

(2)

Separate LM2500+ Model PK gas generator from power turbine per WP 301 00.

(3)

Separate LM2500+ Models GV and PV gas generator from power turbine per WP 301 00 and GEK 105052.

Disconnect external piping and tubing (figure 1) between LM2500+ Model PK gas generator and TMF as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

d.

(1)

Disconnect C-sump oil supply tube from TMF strut cap per SWP 113 01.

(2)

Disconnect C-sump scavenge tube from TMF strut cap per SWP 113 01.

(3)

Disconnect B- and C-sump drain tube from TMF strut cap per SWP 113 01.

(4)

Disconnect five cooling air tubes from TMF strut caps per SWP 113 01.

(5)

Disconnect two HP recoup air manifolds from TMF per SWP 113 01.

(6)

Disconnect C-sump vent tube from TMF strut cap per SWP 113 01

Disconnect external piping and tubing (figure 2) between LM2500+ Models GK, GV, and PV gas generators and TMF as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

4

Disconnect C-sump oil supply tube from TMF strut cap per WP 113 00.




Figure 1. LM2500+ Model PK Turbine Mid Frame Piping Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

5



Figure 2. LM2500+ Models GK, GV, AND PV Turbine Mid Frame Piping 6




e.

(2)

Disconnect C-sump scavenge tube from TMF strut cap per WP 113 00.

(3)

Disconnect B- and C-sump drain tube from TMF strut cap per WP 113 00.

(4)

Disconnect five cooling air tubes from TMF strut caps per WP 113 00.

(5)

Disconnect two HP recoup air manifolds from TMF per WP 113 00.

(6)

Disconnect C-sump vent tube from TMF strut cap per WP 113 00.

Install TMF lift fixture, 1C8351 (figure 3), onto TMF as follows: (1)

Attach hoist to TMF lift fixture, 1C8351, adjustable plate (1). WARNING


Using hoist raise TMF lift fixture, 1C8351, and align behind TMF. (a) Install 12 bolts (4) through TMF lift fixture, 1C8351, boltholes (3) and TMF aft flange. (b) Using bolts (4) and nuts (5), secure TMF lift fixture, 1C8351, to TMF. Tighten bolts hand-tight. (c) Remove ball-lock pin (2) and adjust plate (1) location for proper center of gravity with TMF installed. (d) Install ball-lock pin (2) into plate (1).

f.

Separate TMF from compressor rear frame (CRF) as follows: (1)

Using marking pen, matchmark brackets on CRF aft flange and TMF forward flange.

(2)

Remove 136 bolts, self-locking nuts, and seven rectangular washers over setscrews at CRF-TMF turbine flange. Remove brackets as securing hardware is removed.

(3)

Remove three setscrews from forward face of CRF aft flange at 1:30 o’clock, 7:30 o’clock, and 10:30 o’clock positions (figure 4).

(4)

Install four jackscrews, 1C6804 into CRF aft flange at 1:30 o’clock, 7:30 o’clock, and 10:30 o’clock positions.


7



Figure 3. TMF Lift Fixture, 1C8351 8




Figure 4. CRF-TMF Flange Setscrews WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (5)

Using jackscrews, 1C6804, disengage CRF-TMF flange interference fit. If required, use heat gun to heat CRF flange to ease separation. Remove jackscrews after flanges separate. WARNING


g.

(6)

Using hoist and TMF lift fixture, 1C8351, move TMF away from engine.

(7)

Using four slave bolts, secure HPT stage 2 nozzle to CRF aft flange. Tighten bolts hand-tight.

(8)

Protect exposed No. 5R bearing components per GEK 105054, Chapter 10.

(9)

Cover or cap all exposed gas generator and TMF tubing and piping openings.

Using hoist, lower TMF to working surface. Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

9


7.


h.

Inspect TMF per WP 429 00.

i.

Inspect C-sump and No. 5R bearing per WP 413 00.

j.

For LM2500+ Model PK gas turbine, inspect No. 6R bearing per SWP 413 01.

Turbine Mid Frame Installation. a.

If required, install TMF lift fixture, 1C8351, onto TMF per paragraph 6. step e. CAUTION No. 5R bearing uses matched components. Replacement of No. 5R bearing inner race is required with TMF replacement.

b.

If different TMF than one removed in paragraph 6. is being installed, replace No. 5R bearing inner race per WP 217 00 or SWP 217 01.

c.

Install TMF onto CRF as follows: (1)

Remove four slave bolts that secure HPT stage 2 nozzle to CRF aft flange. WARNING

ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. (2)

Using isopropyl alcohol, thoroughly clean CRF aft flange, HPT stage 2 nozzle flange, and TMF forward flange.

(3)

Uncover or uncap all gas generator and TMF piping and tubing openings.

(4)

Apply petrolatum to No. 5 bearing rollers. Push rollers radially outward to provide as much clearance as possible for HPT rotor aft shaft. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION USE CAUTION WHEN ALIGNING TMF AND GAS GENERATOR. ENSURE TMF IS LOCATED FAR ENOUGH AFT TO PREVENT DAMAGE TO NO. 5R BEARING AND SEALS DURING ALIGNMENT. (5)

10

Using hoist and TMF lift fixture, 1C8351, lift and align TMF behind gas generator.




CAUTION

•

ENSURE TMF AND GAS GENERATOR ARE PROPERLY ALIGNED BEFORE MOVING TMF FORWARD. INACCURATE ALIGNMENT WILL RESULT IN DAMAGE TO NO. 5R BEARING.

•

USE EXTREME CAUTION WHEN MATING TMF TO CRF, OR DAMAGE TO NO. 5R BEARING AND SEALS MAY OCCUR.

(6)

Using hoist and TMF lift fixture, 1C8351, install TMF onto CRF.

(7)

Using thread lubricant, lightly coat bolt threads and contact faces of 136 bolts and self-locking nuts.

(8)

Install three setscrews into CRF aft flange holes to be flush with the forward side of the aft flange.

(9)

Using 136 bolts, self-locking nuts, and seven rectangular washers over setscrews, secure TMF to CRF. Install brackets (figures 5 and 6) per matchmarks made at removal. Tighten bolts finger-tight.

(10) Final tighten 136 bolts as follows: (a) Tighten bolt in bolthole 1 to 162-178 lb in. (18.4-20.1 N⋅m) of torque. (b) Tighten bolt in bolthole 78 to 162-178 lb in. (18.4-20.1 N⋅m) of torque. (c) Tighten bolt in bolthole 34 to 162-178 lb in. (18.4-20.1 N⋅m) of torque. (d) Tighten bolt in bolthole 102 to 162-178 lb in. (18.4-20.1 N⋅m) of torque. (e) Continue tightening bolts, indexing one bolt clockwise, until all bolts are tightened to 162-178 lb in. (18.4-20.1 N⋅m) of torque. d.

Connect external tubing and piping (figure 1) between LM2500+ Model PK gas generator and TMF as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Connect C-sump oil supply tube onto TMF strut cap per SWP 113 01.

(2)

Connect C-sump scavenge tube onto TMF strut cap per SWP 113 01.

(3)

Connect B- and C-sump drain tube onto TMF strut cap per SWP 113 01.


11



Figure 5. LM2500+ Model PK CRF to TMF Flange Brackets 12




Figure 6. LM2500+ Models GK, GV, and PV CRF to TMF Flange Brackets Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

13


e.


(4)

Connect five cooling air tubes onto TMF strut caps per SWP 113 01.

(5)

Connect two HP recoup air manifolds onto TMF per SWP 113 01.

(6)

Connect C-sump vent tube onto TMF strut cap per SWP 113 01.

Connect external tubing and piping (figure 2) between LM2500+ Models GK, GV, and PV gas generator TMF as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

f.

14

(1)

Connect C-sump oil supply tube onto TMF strut cap per WP 113 00.

(2)

Connect C-sump scavenge tube onto TMF strut cap per WP 113 00.

(3)

Connect B- and C-sump drain tube onto TMF strut cap per WP 113 00.

(4)

Connect five cooling air tubes onto TMF strut caps per WP 113 00.

(5)

Connect two HP recoup air manifolds onto TMF per WP 113 00.

(6)

Connect C-sump vent tube onto TMF strut cap per WP 113 00.

Join gas generator and power turbine as follows: (1)

Join LM2500+ Model GK gas generator to power turbine per WP 301 00 and packager’s manual.

(2)

Join LM2500+ Model PK gas generator to power turbine per WP 301 00.

(3)

Join LM2500+ Models GV and PV gas generator to power turbine per WP 301 00 and GEK 105052.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE TURBINE ROTOR REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1- 36 .................. 0 Alphabetical Index Subject

Page

High Pressure Turbine Rotor Installation. ........................................................................ 24 High Pressure Turbine Rotor Removal. ............................................................................. 4


GEK 105054 Volume II WP 201 00 1.


Introduction. This work package contains instructions for removal and installation of high pressure turbine rotor and high pressure turbine stage 2 nozzle assembly.

2.

3.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Turbine Mid Frame Replacement Gas Generator and Power Turbine Separation and Joining Gas Generator Miscellaneous Sump Components Replacement Gas Turbine Miscellaneous Sump Components Replacement

GEK 105054 WP 002 00 WP 200 00

High Pressure Turbine Rotor Inspection Illustrated Parts Breakdown

WP 426 00 GEK 105055

WP 216 00 WP 217 00 SWP 217 01


Part No.

Gage, Vertical Concentricity - Bearing 5 Inner Ring Jackscrews, Flange Disassemble Tool Set Wrench, Spanner - No. 5 Bearing Retaining Nut Wrench, Spanner - High Pressure Turbine Rotor Coupling Nut Stand, Vertical - High Pressure Turbine Rotor Engine Maintenance Unit Fixture, Lift - High Pressure Turbine Rotor, Horizontal Wrench, Spanner - Oil Tube High Pressure Turbine Rotor Puller, Retaining Ring - Bearing 5 Lifteye - High Pressure Turbine Rotor, Aft Wrench, Spline, Direct Drive Tool, Install/Remove - High Pressure Turbine Damper Sleeve Pin, Guide Stage 2 High Pressure Turbine Nozzle Assembly Multiplier, Torque Multiplier, Torque Multiplier, Torque Hydraulic (optional)

1C5937G01 1C6804G04 1C6897G02 1C6950G05 1C8059G01 1C8069G04 2C6058G04 2C6063G01 2C6141G02 2C6341G02 2C6563G01 2C6610G01 Sweeny Model 8200 Sweeny Model 8112 -






Marking Dye Isopropyl Alcohol Lint Free Cloth Lubricating Oil

Dykem DX100 Fed Spec TT-I-735 Local Purchase MIL-L-23699 or MIL-L-7808 Sharpie T.E.C. or Action Marker GE Spec A50TF54 GE Spec A50TF201

Marking Pen Penetrating Oil Thread Lubricant 5.


IPB Figure No./Item

Flexible Oil Seal Flexible Oil Seal Preformed Packing Pressure Lock Seal

21-4 21-4 21-5 10-6


GEK 105054 Volume II WP 201 00 6.


High Pressure Turbine Rotor Removal. a.


b.

Separate gas generator from power turbine per WP 216 00.

c.

Remove turbine mid frame (TMF) per WP 200 00.

d.

Inspect sump components per WP 413 00 or SWP 413 01. NOTE Plugs are located at approximately 3:00 o’clock position near rear of compressor rear frame, aft looking forward.

e.

Remove two borescope plugs (16 and 17, figure 1) and washers from compressor rear frame (CRF) aft case.

f.

Using needle nose pliers or screw driver, remove retaining ring (3, figure 1) and grooved pin (2) that secure No. 5 bearing nut (1) to high pressure turbine (HPT) rotor aft shaft. Place retaining ring and grooved pin into plastic bag and identify.

g.

Using No. 5 bearing retaining nut spanner wrench, 1C6897, remove No. 5 bearing nut (7, figure 2) as follows: WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (1)

Attach hoist to lift hook (1). Lift No. 5 bearing retaining nut spanner wrench, 1C6897.

(2)

Align locator ring (15) onto CRF aft flange (12). Ensure 24 lugs on antitorque ring (6) engage HPT rotor aft shaft scallops.

(3)

Locate six clamps (11) onto forward side of CRF aft flange (12).

(4)

Using handknobs (13), secure spanner wrench, 1C6897, onto CRF aft flange (12). Tighten handknobs hand-tight.

(5)

Install torque tube (4) through spanner wrench, 1C6897. Engage lugs of torque tube to slots in No. 5 bearing nut (7).




Figure 1. HPT Rotor (Sheet 1 of 3) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.







GEK 105054 Volume II WP 201 00 (6)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Install torque multiplier (2) over torque tube (4) onto No. 5 bearing retaining nut spanner wrench, 1C6897. Secure torque multiplier using hardware provided. CAUTION

NO. 5 BEARING SPANNER NUT HAS LEFT-HAND THREADS. ENSURE TORQUE MULTIPLIER IS SET FOR CORRECT DIRECTION, OR DAMAGE TO HPT ROTOR MAY OCCUR. (7)

Using torque multiplier (2), apply torque to turn No. 5 bearing nut (7) clockwise. Loosen No. 5 bearing nut.

(8)

Remove torque multiplier (2) and torque tube (4).

(9)

Remove No. 5 bearing nut (7) from HPT rotor aft shaft (8).

(10) Place No. 5 bearing nut (7) into plastic bag and identify. h.

i.

Remove retaining ring (4, figure 1). If retaining ring cannot be removed by hand, perform following steps: (1)

Insert retaining ring puller, 2C6063, through No. 5 bearing retaining nut spanner wrench, 1C6897, onto HPT rotor aft shaft (2, figure 3).

(2)

Thread retaining ring puller, 2C6063, nut (3) in counterclockwise direction, onto HPT rotor aft shaft (2) until nut seats against No. 5 bearing inner race (1). Tighten retaining ring puller nut hand-tight.

(3)

Loosen eight knurled nuts (9) and position fingers (5) inward to catch retaining ring (10). Tighten knurled knobs hand-tight.

(4)

Insert 0.25 inch (6.4 mm) rod into hole in nut (3).

(5)

Using rod, rotate retaining ring puller, 2C6063, in clockwise direction, until retaining ring puller and retaining ring (10) are removed.

(6)

Remove retaining ring (10) from retaining ring puller, 2C6063. Place retaining ring into plastic bag and identify.

Using oil tube spanner wrench, 2C6058, remove oil tube (9, figure 1) as follows: (1)

Insert oil tube spanner wrench, 2C6058 (1, figure 4), through No. 5 bearing retaining nut spanner wrench, 1C6897, into oil tube (2). Ensure fingers (3) in oil tube spanner wrench engage slots in oil tube.

(2)

Install torque multiplier over oil tube spanner wrench, 2C6058, onto No. 5 bearing retaining nut spanner wrench, 1C6897.




Figure 2. No. 5 Bearing Retaining Nut Spanner Wrench, 1C6897 9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. Retaining Ring Puller, 2C6063 10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



TECH/INSP

WHEN A TORQUE MULTIPLIER IS TO BE USED, IT MUST HAVE ADEQUATE CAPACITY TO MEET THE SPECIFIED TORQUE REQUIREMENTS OF THE OPERATION. THE TORQUE MULTIPLIER MANUFACTURER’S INSTRUCTIONS AND THE INSTRUCTIONS CONTAINED HEREIN MUST BE FOLLOWED EXACTLY TO GUARD AGAINST THE POSSIBLE HAZARDOUS RESULTS OF TOOL MISUSE. CAUTION

•

WHEN USING TORQUE MULTIPLIERS, DO NOT BOUNCE BODY WEIGHT OFF THE 3-FOOT EXTENSION BARS UNDER ANY CIRCUMSTANCES IN AN ATTEMPT TO BREAK TORQUE.

•

DO NOT ADD EXTENSIONS TO THE 3-FOOT EXTENSION BARS.

•

DO NOT USE TORQUE MULTIPLIERS IN SERIES.

•

FAILURE TO USE TOOLS AS INSTRUCTED MAY CAUSE DAMAGE TO TOOLS OR GAS TURBINE. NOTE

•

Due to time at temperature, it may be necessary to use the larger Sweeny 8112 (0-50,000 lb ft [0-67,791 N⋅m]) torque multiplier instead of the Sweeny 8200 (0-12,000 lb ft [0-16,270 N⋅m]) torque multiplier to break torque of the oil tube. Suitable hydraulic multipliers can also be used.

•

Oil tube threads are standard, right-hand threads.

(3)

Using torque multiplier, break torque and unscrew oil tube (2). Ensure oil tube threads are disengaged from HPT rotor coupling nut threads.

(4)

Remove torque multiplier from No. 5 bearing retaining nut spanner wrench, 1C6897.

(5)

Slide ring (6) forward on oil tube spanner wrench, 2C6058 (1).

(6)

Engage three pins (5) of oil tube spanner wrench, 2C6058 (1), into holes of oil tube (2). Pull oil tube from HPT rotor aft shaft.

(7)

Remove and discard flexible seals (7 and 10, figure 1) and preformed pack6.i.(7) ing (6) from oil tube. Discard flexible oil seals and preformed packing.


GEK 105054 Volume II WP 201 00 j.


Remove No. 5 bearing retaining nut spanner wrench, 1C6897, from CRF aft flange as follows: (1)

Loosen six handknobs (13, figure 2) and release clamps (11) that secure locator ring (15) on CRF aft flange (12). WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (2) k.

Using hoist, remove No. 5 bearing retaining nut spanner wrench, 1C6897, from CRF aft flange.

Remove damper sleeve (5, figure 5) as follows: (1)

Loosen locking knobs (10) of damper sleeve removal tool, 2C6563 (1). Open tool completely.

(2)

Insert damper sleeve tool, 2C6563 (1), into HPT rotor aft shaft. When nonadjustable leg (3) bottoms on damper sleeve (5), rotate damper sleeve tool clockwise until tang of leg engages counterclockwise hook (4) of damper sleeve.

(3)

Push adjustable leg (7) of damper sleeve tool, 2C6563 (1), forward until leg contacts damper sleeve (5).

(4)

Rotate adjustable leg (7) of damper sleeve tool, 2C6563 (1), until tang of leg engages clockwise hook (8) of damper sleeve (5).




Figure 4. Oil Tube Spanner Wrench, 2C6058 13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


l.


(5)

Compress damper sleeve (5). Tighten two locking knobs (10) to lock adjustable leg (7) in place.

(6)

Pull damper sleeve (5), with damper sleeve tool, 2C6563 (1), attached, from HPT rotor aft shaft.

(7)

Remove damper sleeve from damper sleeve tool, 2C6563 (1).

Remove HPT rotor coupling nut (13, figure 1) and HPT rotor as follows: CAUTION PENETRATING OIL WD40 SHALL NOT BE USED ON GAS GENERATOR OR GAS TURBINE. LIQUID WRENCH NO. 1 IS AN APPROVED SUBSTITUTE. (1)

Using penetrating oil, lubricate HPT rotor coupling nut.

(2)

Rotate HPT rotor to ensure oil penetrates full circumference of threads.

(3)

Install HPT rotor coupling nut spanner wrench, 1C6950 (1, figure 6), and HPT rotor lift fixture, 1C8069 (3), onto aft end of HPT rotor as follows: (a) Ensure T-handle jackscrews, 1C6950P14 (10), in outer flange of HPT rotor coupling nut spanner wrench, 1C6950 (1), are retracted. Move clamps, 1C6950P06 (2), up and out of way. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (b) Using hoist, install HPT rotor lift fixture, 1C8069 (3), around HPT rotor coupling nut spanner wrench, 1C6950 (1). (c) Using handknobs (12), secure HPT rotor lift fixture, 1C8069 (3), around HPT rotor coupling nut spanner wrench, 1C6950 (1). Tighten handknobs hand-tight. (d) Adjust HPT rotor lift fixture, 1C8069, center of gravity as necessary. (e) Position HPT rotor lift fixture/spanner wrench assembly behind aft end of HPT rotor. (f) Using marking pen, matchmark one HPT rotor blade to HPT stage 2 nozzle. Matchmark HPT stage 2 nozzle to HPT rotor lift fixture, 1C8069 (3) lift arm.




Figure 5. Damper Sleeve Tool, 2C6563 15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 6. HPT Rotor Coupling Nut Spanner Wrench, 1C6950 16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



CLAMPS SHALL ENGAGE HPT STAGE 2 NOZZLE ASSEMBLY FLANGE ONLY. DO NOT INSTALL CLAMPS OVER CRF AFT FLANGE. NOTE Ensure lugs on HPT rotor coupling nut spanner wrench, 1C6950, engage slots on aft face of HPT rotor stage 2 disk. (g) Install HPT rotor coupling nut spanner wrench, 1C6950 (6, figure 7), onto HPT rotor and adjust clamps, 1C6950P06 (2), to engage HPT stage 2 nozzle assembly (4). Tighten clamps hand-tight. (h) Extend T-handle jackscrews, 1C6950P14 (5), through HPT rotor coupling nut spanner wrench, 1C6950, outer ring, and finger-tighten against HPT aft shroud support (7). WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. (4)

Using isopropyl alcohol, clean threads of pilot nut, 1C6950P03 (5, figure 6) and locknut, 1C6950P04 (7). Examine threads for damage and repair as necessary. CAUTION

ENSURE PILOT NUT IS PROPERLY INSTALLED AND SECURED IN HPT ROTOR COUPLING NUT SPANNER WRENCH, 1C6950, TO PREVENT SEPARATION OF HPT ROTOR ASSEMBLY AND SPANNER WRENCH. NOTE HPT rotor aft shaft has left-hand threads. (5)

Install pilot nut, 1C6950P03 (5), onto HPT rotor aft shaft. Tighten finger-tight.




Figure 7. HPT Rotor Removal Using HPT Coupling Nut Spanner Wrench, 1C6950 (6)

Using wrench, 1C6950P05 (9), tighten pilot nut, 1C6950P03 (5) hand-tight.

(7)

Carefully install torque tube, 1C6950P02 (6), into HPT rotor aft shaft until HPT rotor coupling nut (13, figure 1) is engaged.

(8)

Install lifteye, 2C6141 (11, figure 6), into torque tube, 1C6950P02 (6). NOTE

Locknut shall be flush or below surface of HPT rotor coupling nut spanner wrench, 1C6950. (9)

Using wrench, 1C6950P05 (9), install locknut, 1C6950P04 (7) to lock torque tube, 1C6950P02 (6) into place.




•

WHEN USING TORQUE MULTIPLIER, ENSURE IT HAS ADEQUATE CAPACITY TO MEET SPECIFIED TORQUE REQUIREMENTS OF OPERATION.

•

FOLLOW TORQUE MULTIPLIER MANUFACTURER'S INSTRUCTIONS, AS WELL FOLLOWING STEPS, TO GUARD AGAINST POSSIBLE HAZARDOUS RESULTS OF TOOL MISUSE.

(10) Install torque multiplier (8) onto HPT rotor coupling nut spanner wrench, 1C6950 (1). CAUTION GUIDE PINS SHALL BE USED WHEN REMOVING NOZZLE ASSEMBLY TO LESSEN POSSIBILITY OF DAMAGE TO AIR SEALS. (11) Obtain guide pins, 2C6610, or locally manufacture eight guide pins (figure 8). (12) Install eight guide pins, 2C6610, through larger boltholes in HPT rotor coupling nut spanner wrench, 1C6950 (1, figure 6). NOTE Ensure guide pins, 2C6610, are seated against CRF aft flange prior to removing HPT stage 2 nozzle assembly. (13) Using nuts, secure guide pins, 2C6610, to CRF aft flange. Tighten nut hand-tight. (14) Install four jackscrews, 1C6804 (1, figure 7) into CRF aft flange (3). (15) Thread jackscrews, 1C6804 (1), into holes until jackscrews just touch HPT stage 2 nozzle assembly (4).




Figure 8. Guide Pins, 2C6610




WHEN A TORQUE MULTIPLIER IS TO BE USED, IT MUST HAVE ADEQUATE CAPACITY TO MEET THE SPECIFIED TORQUE REQUIREMENTS OF THE OPERATION. THE TORQUE MULTIPLIER MANUFACTURER’S INSTRUCTIONS AND THE INSTRUCTIONS CONTAINED HEREIN MUST BE FOLLOWED EXACTLY TO GUARD AGAINST THE POSSIBLE HAZARDOUS RESULTS OF TOOL MISUSE. CAUTION

•

WHEN USING TORQUE MULTIPLIERS, DO NOT BOUNCE BODY WEIGHT OFF THE 3-FOOT EXTENSION BARS UNDER ANY CIRCUMSTANCES IN AN ATTEMPT TO BREAK TORQUE.

•

DO NOT ADD EXTENSIONS TO THE 3-FOOT EXTENSION BARS.

•

DO NOT USE TORQUE MULTIPLIERS IN SERIES.

•

FAILURE TO USE TOOLS AS INSTRUCTED MAY CAUSE DAMAGE TO TOOLS OR GAS TURBINE.

•

THE FOLLOWING TASK IS CRITICAL AND SHALL BE PERFORMED WITH EXTREME CARE TO PREVENT DAMAGE TO HPT AFT SHAFT THREADS, HPT ROTOR BLADES, VANES, AND SEALS.

•

AS HPT ROTOR COUPLING NUT IS LOOSENED AND HPT ROTOR MOVES AFT, JACKSCREWS, 1C6804, SHALL BE USED TO MOVE HPT STAGE 2 NOZZLE AFT WITH HPT ROTOR AND, AT THE SAME TIME, THE HOIST SHALL BE MOVED AFT TO KEEP HPT ROTOR HORIZONTAL, PREVENTING EXCESSIVE PRESSURE ON HPT ROTOR COUPLING NUT THREADS.

•

TO PREVENT DAMAGE TO HPT ROTOR COUPLING NUT MATING FACES OR THREADS DUE TO BINDING, ADJUST CENTER OF GRAVITY FOR HPT ROTOR COUPLING NUT SPANNER WRENCH, 1C6950 AND ATTACHED HPT ROTOR PRIOR TO BREAKING TORQUE. NOTE

HPT rotor coupling nut threads are standard, right-hand threads. (16) Using torque multiplier (8, figure 6), break torque on HPT rotor coupling nut. (17) Slowly and carefully loosen HPT rotor coupling nut approximately two turns.




(18) Using jackscrews, 1C6804 (1, figure 7), move HPT stage 2 nozzle assembly (4) aft. Move HPT rotor lift fixture/spanner wrench assembly and hoist aft with HPT rotor to prevent excessive pressure on shaft threads. (19) Remove torque multiplier (8, figure 6) from HPT rotor coupling nut spanner wrench, 1C6950 (1). (20) Using spline wrench, 2C6341 (14), positioned over torque tube, 1C6950P02 (6), aft spline teeth, continue to loosen HPT rotor coupling nut. (21) Loosen HPT rotor coupling nut until threads are completely disengaged and HPT rotor forward shaft is free of high pressure compressor (HPC) aft shaft. (22) When HPT rotor is free of HPC rotor aft shaft and HPT stage 2 nozzle is free of CRF, carefully move assembly aft until clear of gas generator. m. Attach second hoist to lifteye, 2C6141 (11). WARNING

•

Use correct lifting equipment and techniques. Stay out from under suspended loads to prevent injury.

•

When installing equipment, keep hands clear of equipment interface/ attaching points to prevent pinch injury.

n.

Using two hoists, rotate HPT rotor to vertical position.

o.

Install HPT rotor and HPT stage 2 nozzle into HPT rotor vertical stand, 1C8059 (figure 9). Adjust stand, as necessary, to support HPT rotor and HPT stage 2 nozzle.

p.

Remove HPT rotor coupling nut spanner wrench, 1C6950 (1, figure 6), and HPT rotor lift fixture, 1C8069 (3), from rear of HPT rotor as follows: CAUTION EXERCISE CARE WHEN HANDLING HPT ROTOR AFTER HPT ROTOR COUPLING NUT SPANNER WRENCH, 1C6950 AND HPT ROTOR LIFT FIXTURE, 1C8069, IS REMOVED. THE HPT STAGE 2 NOZZLE ASSEMBLY WILL BE LOOSE ON HPT ROTOR AND SUBJECT TO DAMAGE. (1)

Using wrench, 1C6950P05 (9), remove locknut, 1C6950P04 (7). Locknut has righthand threads.

(2)

Remove torque tube, 1C6950P02 (6).

(3)

Using wrench, 1C6950P05 (9), remove pilot nut, 1C6950P03 (5). Pilot nut has lefthand threads.




Figure 9. HPT Rotor Vertical Stand, 1C8059 (4)

Retract T-handle jackscrews, 1C6950P14 (10).

(5)

Install lift nut, 1C6950P20 (13), onto HPT rotor coupling spanner nut wrench, 1C6950 (1).

(6)

Attach hoist onto lifteye of lift nut, 1C6950P20 (13).

(7)

Using hoist, lift and remove HPT rotor coupling nut spanner wrench, 1C6950 (1), and HPT rotor lift fixture, 1C8069 (3) from HPT rotor.

q.

Remove jackscrews, 1C6804, from CRF.

r.

If desired, remove guide pins, 2C6610, from CRF.

s.

Remove pressure lock seal (14, figure 1) from aft end of HPC rotor. Discard pressure lock seal.

t.

Inspect HPT rotor per WP 426 00.


GEK 105054 Volume II WP 201 00 7.


High Pressure Turbine Rotor Installation. NOTE HPT rotor and HPT stage 2 nozzle are assumed to be in vertical stand, 1C8059. a.

If removed, install pressure lock seal (14, figure 1) into aft end of HPC rotor aft shaft.

b.

Install HPT rotor coupling nut spanner wrench, 1C6950 (1, figure 6), and HPT rotor lift fixture, 1C8069 (3), onto aft end of HPT rotor as follows: WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (1)

If removed, using hoist, attach HPT rotor lift fixture, 1C8069 (3), to HPT rotor coupling nut spanner wrench, 1C6950 (1). Secure with handknobs (12). Tighten handknobs hand-tight.

(2)

Adjust center of gravity for HPT rotor lift fixture, 1C8069, with HPT rotor coupling nut spanner wrench, 1C6950, and HPT rotor attached.

(3)

Ensure T-handle jackscrews, 1C6950P14 (10), in outer flange of HPT rotor coupling nut spanner wrench, 1C6950 (1), are installed and retracted.

(4)

Move clamps, 1C6950P06 (2), up and out of way.

(5)

Install lift nut, 1C6950P20 (13), onto HPT rotor coupling nut spanner wrench, 1C6950 (1).

(6)

Attach second hoist to lift nut, 1C6950P20.

(7)

Using second hoist, tilt and transfer HPT rotor lift fixture, 1C8069 (3), and HPT rotor coupling nut spanner wrench, 1C6950 (1), to vertical position.




ENSURE BORESCOPE HOLE IN HPT STAGE 2 NOZZLE IS LOCATED AT 3:00 O’CLOCK POSITION IN RELATION TO LIFT FIXTURE ARM, OR BORESCOPE OF HPT ROTOR WILL NOT BE POSSIBLE. NOTE

•

No. 5 bearing inner race shall be in place before HPT rotor coupling nut spanner wrench, 1C6950, is installed. If No. 5 bearing race is not in place, refer to WP 217 00 or SWP 217 01.

•

If HPT stage 2 nozzle has 12:00 o’clock position marked, align HPT rotor lift fixture, 1C8069, lift arm with mark. If lift arm matchmark is not present, ensure HPT stage 2 nozzle borescope opening is at 3:00 o’clock position to lift arm.

•

Spanner wrench, 1C6950, has 24 lugs which engage scallops on HPT rotor aft shaft for antitorque purposes. Ensure these lugs are fully engaged with HPT rotor aft shaft.

(8)

Install HPT rotor lift fixture, 1C8069 (3), and HPT rotor coupling nut spanner wrench, 1C6950 (1), onto HPT rotor aft shaft. CAUTION

CLAMPS SHALL ENGAGE HPT STAGE 2 NOZZLE ASSEMBLY FLANGE. (9)

Adjust clamps, 1C6950P06 (2, figure 7), to engage HPT stage 2 nozzle assembly (4).

(10) Adjust T-handle jackscrews, 1C6950P14 (5), on HPT rotor coupling nut spanner wrench (6). Tighten T-handle jackscrews finger-tight against HPT aft shroud support (7). CAUTION

•

ENSURE PILOT NUT IS PROPERLY INSTALLED AND SECURED IN HPT ROTOR COUPLING NUT SPANNER WRENCH TO PREVENT SEPARATION OF HPT ROTOR ASSEMBLY AND LIFT FIXTURE.

•

HPT ROTOR AFT SHAFT HAS LEFT-HAND THREADS.

(11) Remove lift nut, 1C6950P20 (13, figure 6), and hoist. (12) Install pilot nut, 1C6950P03 (5), onto HPT rotor aft shaft. Tighten pilot nut finger-tight. (13) Using wrench, 1C6950P05 (9), tighten pilot nut, 1C6950P03 (5), hand-tight.




•

HPT ROTOR AFT SHAFT HAS LEFT-HAND THREADS.

•

ENSURE PILOT NUT, 1C6950P03, IS PROPERLY INSTALLED AND SECURED IN HPT ROTOR COUPLING NUT SPANNER WRENCH, 1C6950, TO PREVENT SEPARATION OF HPT ROTOR ASSEMBLY AND HPT ROTOR LIFT FIXTURE, 1C8069.

(14) Carefully install torque tube, 1C6950P02 (6), into rear of HPT rotor. (15) Thread torque tube, 1C6950P02 (6), into HPT rotor coupling nut (13, figure 1) at front of HPT rotor. (16) Install lifteye, 2C6141 (11, figure 6), into torque tube, 1C6950P02 (6). WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. (17) Using isopropyl alcohol and cleaning cloth, clean threads of locknut, 1C6950P04 (7). Examine threads for damage and repair as necessary. NOTE Locknut shall be flush or below surface of HPT rotor coupling nut spanner wrench, 1C6950. (18) Using locknut, 1C6950P04 (7), lock torque tube, 1C6950P02 (6), into place. Use wrench, 1C6950P05 (9), to tighten locknut securely. (19) Attach hoist to lifteye, 2C6141 (11). (20) Attach second hoist to HPT rotor lift fixture, 1C8069 (3). WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (21) Using two hoists, raise HPT rotor and HPT stage 2 nozzle from HPT rotor vertical stand, 1C8059. (22) Transfer HPT rotor lift fixture, 1C8069 (3), HPT rotor coupling nut spanner wrench, 1C6950 (1), and HPT rotor to horizontal position. (23) Adjust HPT rotor lift fixture 1C8069 (3), for proper center of gravity. (24) Detach hoist from lifteye, 2C6141 (11). 26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



(25) Position HPT rotor and HPT stage 2 nozzle assembly behind gas generator. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. c.

Using isopropyl alcohol, clean threads and mate face of HPC rotor aft shaft. Thoroughly clean threads and allow surface to dry.

d.

Inspect HPC rotor aft shaft threads for burrs. Using fine stone and fiber wheel, remove any burrs found. CAUTION ENSURE NO THREAD LUBRICANT IS PRESENT ON SURFACE DE (FIGURE 1) OF HPC ROTOR AFT SHAFT.

e.

Using thread lubricant, lightly coat aft two to five threads of HPC aft shaft. Do not overapply thread lubricant.

f.

Using isopropyl alcohol, clean threads, forward face of HPT rotor coupling nut, mate face, and HPT rotor coupling nut seating surface of HPT rotor forward shaft. Thoroughly clean threads and allow surface to dry.

g.

Check HPT rotor coupling nut threads for burrs. Using fine stone and fiber wheel, remove any burrs found.

h.

Using thread lubricant, thoroughly coat surface AN (figure 1) of HPT rotor coupling nut and all HPT rotor coupling nut threads. Overall thread coverage required. Remove excess thread lubricant coating. CAUTION PRESSURE LOCK SEAL SHALL BE INSTALLED IN AFT INSIDE DIAMETER OF HPC ROTOR AFT SHAFT TO PREVENT AIR LEAKAGE.

i.

Install new pressure lock seal (14) in HPC rotor aft shaft. CAUTION DO NOT TOUCH BEARING SURFACES, OR DAMAGE TO BEARINGS MAY OCCUR.

j.

Inspect in and around No. 4 bearing sump area for foreign material. Remove material as required. 27 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 201 00 k.


Install HPT rotor and HPT stage 2 nozzle as follows: (1)

If HPT rotor and HPT stage 2 nozzle are same assembly removed in paragraph 6, ensure matchmarks made at disassembly are aligned. NOTE

The Z mark on HPT rotor forward shaft shall be aligned to O or LO mark on HPC rotor aft shaft. (2)

If HPT rotor and HPT stage 2 nozzle are different than removed in paragraph 6, align Z mark on OD of HPT rotor forward shaft with LO or O mark on aft face of HPC rotor aft shaft as follows: (a) Locate Z mark on HPT rotor forward shaft and O or LO mark on HPC rotor aft shaft. Turn both rotors so marks are aligned and at 12:00 o’clock position. (b) Using marking pen, matchmark Z on aft face of HPT rotor stage 2 disk in line with Z mark on HPT rotor forward shaft. CAUTION

•

EXERCISE EXTREME CARE DURING INSTALLATION OF HPT ROTOR TO PREVENT DAMAGE TO SEALS.

•

HPT ROTOR SHALL REMAIN HORIZONTAL AT ALL TIMES DURING INSTALLATION TO PREVENT DAMAGE TO FORWARD SHAFT AND HPT ROTOR COUPLING NUT THREADS. NOTE

Ensure borescope hole in HPT stage 2 nozzle assembly is aligned with borescope hole near rear of CRF. (3)

If removed, install guide pins, 2C6610 (figure 8), into CRF aft flange.

(4)

Visually align HPT rotor forward shaft with aft shaft of HPC rotor.

(5)

Carefully move HPT rotor forward over HPC rotor aft shaft until splines start to engage.

(6)

Adjust HPT stage 2 nozzle, as necessary, to align borescope hole.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION DO NOT EXCEED MAXIMUM ALLOWABLE TORQUE OF 10,000 LB FT (13,560 N⋅M) OR TOTAL OF SIX COMPLETE TORQUING CYCLES OF HPT COUPLING NUT. NOTE HPT rotor coupling nut has standard right-hand threads. (7)

Using spline wrench, 2C6341 (14, figure 6), turn torque tube, 1C6950P02 (6), clockwise. Engage HPT rotor coupling nut threads.

(8)

Continue moving HPT rotor forward and turning torque tube until HPT rotor coupling nut is hand-tight.

(9)

Remove spline wrench, 2C6341 (14), from HPT coupling nut spanner wrench, 1C6950 (1). CAUTION

RUNNING TORQUE OF HPT ROTOR COUPLING NUT SHALL NOT EXCEED 200 LB FT (271.2 N⋅M) DURING TIGHTENING OPERATION. IF TORQUE SHOULD INCREASE SIGNIFICANTLY PRIOR TO SEATING, REMOVE HPT ROTOR AND INSPECT FOR CAUSE OF TORQUE INCREASE. (10) Install torque multiplier (8) to rear of HPT rotor coupling nut spanner wrench, 1C6950 (1). Use hoist, if necessary, to support torque multiplier. (11) Using torque multiplier, tighten HPT rotor coupling nut to 7,500 lb ft (10,170 N⋅m) of torque. (12) Reverse direction of torque multiplier travel. (13) Using torque multiplier, loosen HPT rotor coupling nut to 500-1,500 lb ft (678-2,034 N⋅m) of torque. (14) Reverse direction on torque multiplier. (15) Retighten HPT rotor coupling nut to 2,000 lb ft (2,712 N⋅m) of torque. Record wrench angle. WA




•

If torque multiplier has no protractor, using marking pen, matchmark angular relationship of wrench to torque tube to wrench housing.

•

New or replated HPT rotor coupling nuts shall achieve angle of 28-30 degrees at lower torque value, usually less than 8,000 lb ft (10,848 N⋅m). Reuse of HPT rotor coupling nut increases torque requirement. Six or more reuses may raise torque requirements over maximum allowable 12,000 lb ft (16,272 N⋅m) limit.

•

Torquing, then loosening HPT rotor coupling nut constitutes one use of torquing cycle.

(16) Increase torque until wrench angle is 28-30 degrees greater than that recorded at 2,000 lb ft (2,712 N⋅m) or until torque is 10,000 lb ft (13,560 N⋅m), whichever occurs first. (17) If wrench angle is 28-30 degrees greater than that recorded at 2,000 lb ft (2,712 N⋅m) and torque is less than 10,000 lb ft (13,560 N⋅m), HPT rotor coupling nut is acceptable. (18) If above requirements are not met, perform the following: (a) Remove HPT rotor per paragraph 6, step l. (b) Clean and relubricate HPT rotor coupling nut per steps c. through h. CAUTION DO NOT EXCEED MAXIMUM ALLOWABLE TORQUE OF 10,000 LB FT (13,560 N⋅M) OR TOTAL OF SIX COMPLETE TORQUING CYCLES OF HPT ROTOR COUPLING NUT. IF THESE LIMITS ARE EXCEEDED, FIELD REPLATE OR REPLACE HPT ROTOR COUPLING NUT. (c) Reinstall HPT rotor coupling nut per steps k.(7) through (17). NOTE HPT rotor aft shaft has left-hand threads (19) Remove torque multiplier (8). (20) Using wrench, 1C6950P05 (9), remove locknut, 1C6950P04 (7), and pull torque tube, 1C6950P02 (6), out rear of HPT rotor coupling nut spanner wrench, 1C6950 (1).



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE Pilot nut, 1C6950P03 has left-hand threads. (21) Using wrench, 1C6950P05 (9), remove pilot nut, 1C6950P03 (5). WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (22) Install lift nut, 1C6950P20 (13), onto HPT rotor coupling nut spanner wrench, 1C6950 (1). (23) Attach hoist onto lifteye of lift nut, 1C6950P20 (13).

(24) Using hoist, remove HPT rotor coupling nut spanner wrench, 1C6950 (1), and HPT rotor lift fixture, 1C8069 (3), as unit. (25) Remove locally manufactured guide pins, 2C6610 (figure 8) from CRF aft flange. l.

Using concentricity gage, 1C5937, measure concentricity of No. 5 bearing inner race (12, figure 1) on HPT rotor aft shaft as follows: (1)

Install support slightly aft of HPT rotor and adjust indicator against 6:00 o’clock position of No. 5 bearing inner race. NOTE

Allow HPT rotor time to stabilize before each reading. (2)

Using concentricity gage, 1C5937, measure concentricity at 12 equally spaced points. Maximum runout is 0.010 inch (0.25 mm) FIR.

(3)

If runout is not within limits, remove HPT rotor and reinstall into different circumferential positions to obtain required concentricity.

(4)

Remove concentricity gage, 1C5937, and support.

m. Install damper sleeve into HPT rotor as follows: (1)

Install damper sleeve onto damper sleeve tool, 2C6563, per paragraph 6, step k.

(2)

Using damper sleeve tool, 2C6563 (1, figure 5), compress damper sleeve (5).

(3)

Install damper sleeve (5) into HPT rotor aft shaft. 31



n.


(4)

Seat damper sleeve (5) against ID of pressure tube.

(5)

Remove damper sleeve tool, 2C6563, from damper sleeve.

(6)

Remove damper sleeve tool from HPT rotor aft shaft.

Install flexible oil seals (7 and 10, figure 1) and preformed packing (6) onto oil tube (9) as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Lubricate flexible oil seals (7 and 10) and preformed packing (6) with lubricating oil.

(2)

Install flexible oil seals (7 and 10) into two large grooves near aft end of oil tube (9).

(3)

Install preformed packing (6) into small groove in aft end of oil tube (9).

o.

Using bright light and mirror, visually inspect HPC rotor aft shaft to ensure pressure lock seal is properly seated.

p.

Install oil tube (9) into HPT rotor as follows: (1)

Apply light coating of marking dye to forward end of oil tube (9).

(2)

Coat threads of oil tube (9) with thread lubricant.

(3)

Install oil tube (9) into aft end of HPT rotor. Hand-tighten, as far as possible.

(4)

Attach hoist to No. 5 bearing retaining nut spanner wrench, 1C6897, lift hook (1, figure 2). WARNING


Using hoist, lift and align locator ring (15) onto CRF aft flange (12). Ensure 24 lugs on antitorque ring (6) engage HPT rotor aft shaft scallops.

(6)

Locate six clamps (11) onto forward side of CRF aft flange (12).




Using handknobs (13), secure No. 5 bearing retaining nut spanner wrench, 1C6987, onto CRF aft flange (12). Tighten handknobs hand-tight. NOTE

Oil tube threads are standard, right-hand threads. (8)

Install and engage three pins (5, figure 4) of oil tube spanner wrench, 2C6058 (1), into holes of oil tube (2).

(9)

Install oil tube spanner wrench, 2C6058 (1), and oil tube (2) through No. 5 bearing retaining nut spanner wrench, 1C6987.

(10) Engage fingers (3) with slots at rear of oil tube (2). (11) Disengage three pins (5) from oil tube spanner wrench, 2C6058 (1). (12) Slide ring (6) and pins (5) aft on oil tube spanner wrench, 2C6058 (2). (13) Install torque multiplier over oil tube spanner wrench, 2C6058 (1). (14) Secure torque multiplier to No. 5 bearing retaining nut spanner wrench, 1C6987. (15) Using torque multiplier, tighten oil tube (2) to 600-800 lb ft (814-1085 N⋅m) of torque. (16) Measure and record dimension X (figure 1) from aft face of oil tube (9) to aft face of HPT rotor aft shaft (11). Dim X (17) Using marking pen, mark point of measurement of dimension X on HPT rotor aft shaft only. (18) Reverse direction of torque multiplier. (19) Using torque multiplier and oil tube spanner wrench, 2C6058, remove oil tube (2, figure 4) from HPT rotor. (20) Visually inspect oil tube (2) and seating surface inside HPC rotor aft shaft for continuous marking dye pattern to ensure oil tube has seated. (21) Using isopropyl alcohol and lint-free cloth, remove marking dye from oil tube (2). (22) Reapply thread lubricant as necessary. (23) Reverse direction of torque multiplier. (24) Reinstall oil tube (2) into HPT rotor. 33 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



(25) Using torque multiplier and oil tube spanner wrench, 2C6058 (1), tighten oil tube to 1,000 lb ft (1,356 N⋅m) of torque. (26) Reverse direction of torque multiplier. (27) Using torque multiplier and oil tube spanner wrench, 2C6058 (1), break torque. (28) Reverse direction of torque multiplier. (29) Using torque multiplier and oil tube spanner wrench, 2C6058 (1), retighten oil tube (2) to 1,000 lb ft (1,356 N⋅m) of torque. (30) Visually check to ensure one slot in HPT rotor aft shaft (11, figure 1) aligns to slot in oil tube (9) to allow installation of retaining ring (4). If necessary, increase torque on oil tube to align slots. Do not exceed 1200 lb ft (1,627 N⋅m) of torque. (31) Remove torque multiplier and oil tube spanner wrench, 2C6058, from No. 5 bearing retaining nut spanner wrench, 1C6987. q.

Install retaining ring (4) as follows: (1)

Trial fit retaining ring (4).

(2)

Remove retaining ring (4). If necessary, reinstall torque multiplier and oil tube wrench to increase torque slightly to align retaining ring. Do not exceed 1200 lb ft (1627 N⋅m) of torque.

(3)

Measure dimension X (figure 1) at same point marked in step p.17. Measurement shall be equal to or less than measurement made in step p.16. Dim X CAUTION

RETAINING RING SHALL BE INSTALLED WITH OUTER KEY AFT TO ALLOW PROPER THREAD ENGAGEMENT BETWEEN NO. 5 BEARING NUT AND HPT ROTOR AFT SHAFT. (4)

Install retaining ring (4) onto HPT rotor aft shaft. NOTE

HPT rotor aft shaft has left-hand threads. r.

Install No. 5 bearing nut (1) onto HPT rotor aft shaft as follows: (1)

Using thread lubricant, coat threads of No. 5 bearing nut (1) and HPT rotor aft shaft (11).




Install No. 5 bearing nut (1) onto HPT rotor aft shaft (11).

(3)

Using torque tube (4, figure 2) and torque multiplier (2), tighten No. 5 bearing nut to 450 lb ft (610 N⋅m) of torque.

(4)

Using 0.001 inch (0.03 mm) feeler gage, ensure No. 5 bearing inner race is properly seated.

(5)

Remove torque multiplier (2) and torque tube (4) from No. 5 bearing retaining nut spanner wrench, 1C6987. CAUTION

USE ONLY APPROVED MARKING MATERIAL TO PREVENT DAMAGE TO NO. 5 BEARING INNER RACE. (6)

Inspect No. 5 bearing nut (1, figure 1) and HPT rotor aft shaft (11) for alignment of pinholes.

(7)

If no pinholes are not aligned, proceed as follows: (a) Select pinhole in HPT rotor aft shaft (11) nearest pin hole in No. 5 bearing nut (1) accessible by counterclockwise rotation of No. 5 bearing nut. (b) Using marking pen, mark No. 5 bearing inner race (12) where pinhole in HPT rotor aft shaft is located. (c) Using marking pen, mark next No. 5 bearing nut (1) pinhole located clockwise from mark on No. 5 bearing inner race (12). Distance between marks is equal to misalignment of pinholes. (d) Install torque tube (4, figure 2) and torque multiplier (2) onto No. 5 bearing retaining nut spanner wrench, 1C6897. NOTE

HPT rotor aft shaft has left-hand threads. (e) Using torque multiplier (2) and torque tube (4), increase torque to No. 5 bearing nut to align marks on No. 5 bearing nut and No. 5 bearing inner race. Do not exceed 500 lb ft (678 N⋅m) of torque. (f) Remove torque multiplier (2) and torque tube (4) from No. 5 bearing retaining nut spanner wrench.


GEK 105054 Volume II WP 201 00 s.


Remove No. 5 bearing retaining nut spanner wrench, 1C6897, from CRF aft flange as follows: (1)

Loosen six handknobs (13) and release clamps (11) that secure locator ring (15) on CRF aft flange (12). WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (2) t.

Using hoist, remove No. 5 bearing retaining nut spanner wrench, 1C6897, from CRF aft flange.

Using feeler gage, measure and record clearance, dimension Y (figure 1), between No. 5 bearing nut (1) and aft face of HPT rotor shaft (11) as follows: (1)

Measure at three equally spaced locations.

(2)

Minimum clearance shall be 0.002 in. (0.05 mm). CAUTION

LOCKING PIN SHALL BE PROPERLY INSTALLED AND SECURED BY RETAINING RING TO PREVENT NO. 5 BEARING NUT FROM COMING LOOSE DURING OPERATION. u.

Using pin (2), grooved end aft, secure No. 5 bearing nut (1) to HPT rotor aft shaft (11).

v.

Using retaining ring (3) secure pin (2) in No. 5 bearing nut (1). Ensure retaining ring is fully seated into retaining groove of No. 5 bearing nut.

w.

Install borescope plugs (16 and 17) and washer into CRF as follows: (1)

Using thread lubricant, coat washer contact face and borescope plug threads.

(2)

Tighten borescope plug (16) to 300-330 lb in. (33.9-37.3 N⋅m) of torque and safety wire.

(3)

Tighten borescope plug (17) to 205-225 lb in. (23.2-25.4 N⋅m) of torque and safety wire.

x.

Install four setscrews into forward face of CRF rear flange at 1:30 o’clock, 4:30 o’clock, and 7:30 o’clock positions. Tighten setscrews flush with flange face.

y

Install TMF per WP 200 00.

z.

Join gas generator to power turbine assembly per WP 216 00.





TECHNICAL PROCEDURES HIGH PRESSURE TURBINE STAGE 2 NOZZLE ASSEMBLY REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Turbine Stage 2 Nozzle Assembly Installation......................................... High Pressure Turbine Stage 2 Nozzle Assembly Removal..............................................

3 3




Introduction. This work package provides instructions for the removal and installation of the high pressure turbine (HPT) stage 2 nozzle assembly.

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices High Pressure Turbine Rotor Replacement High Pressure Turbine Rotor Blade Replacement High Pressure Turbine Stage 2 Nozzle Inspection

GEK 105054 WP 002 00 WP 201 00 WP 202 00 WP 428 00


Part No.

Sling, Lift - High Pressure Turbine, Stage 2 Nozzle Assembly

1C5964G01



Marking Pen

Sharpie T.E.C. or Action marker





High Pressure Turbine Stage 2 Nozzle Assembly Removal. a.

Comply with all instructions contained in WP 002 00. CAUTION HPT ROTOR ASSEMBLY AND HPT STAGE 2 NOZZLE MAY BE A MATCHED SET. IF A NEW HPT ROTOR ASSEMBLY IS TO BE INSTALLED, ENSURE HPT STAGE 1 AND STAGE 2 SHROUDS ARE GROUND TO GIVE REQUIRED BLADE TIP-TO-SHROUD CLEARANCE.

b.

Remove HPT rotor from engine per WP 201 00. NOTE HPT rotor and HPT stage 2 nozzle are assumed to be properly installed in HPT rotor vertical stand, 1C8059.

c.

Remove HPT stage 2 rotor blades per WP 202 00.

d.

Using marking pen, matchmark HPT stage 2 nozzle position relative HPT rotor. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY.

7.

e.

Using lift sling, 1C5964, remove HPT stage 2 nozzle assembly from HPT rotor. Place onto flat surface.

f.

Inspect HPT stage 2 nozzle per WP 428 00.

High Pressure Turbine Stage 2 Nozzle Assembly Installation. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. a.

Using lift sling, 1C5964, install HPT stage 2 nozzle onto HPT rotor. Ensure HPT stage 2 nozzle assembly is installed forward end down.

b.

If installing same HPT stage 2 nozzle removed in step 6. (d), align matchmarks made during removal of HPT stage 2 nozzle assembly.

c.

Install HPT rotor stage 2 rotor blades per WP 202 00.

d.

Install HPT rotor into engine per WP 201 00. 3/(4 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.




TECHNICAL PROCEDURES HIGH PRESSURE TURBINE STAGE 1 NOZZLE ASSEMBLY REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 8 ................... 0


Page

High Pressure Turbine Stage 1 Nozzle Installation.......................................................... High Pressure Turbine Stage 1 Nozzle Removal...............................................................

7 3




Introduction. This work package contains instructions for removal and installation of high pressure turbine (HPT) stage 1 nozzle assembly.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Turbine Mid Frame Replacement High Pressure Turbine Rotor Replacement Gas Generator and Power Turbine Separation and Joining High Pressure Turbine Stage 1 Nozzle Inspection

GEK 105054 WP 002 00 WP 200 00 WP 201 00


Part No.

Tool Set, Jackscrew - Disassemble Flanges Fixture, Lift - HPT Nozzle, Stage 1 Gun, Heat

1C6804G04 1C8217G01 Local Purchase



Barrier Paper

MIL-B-121, Type I, Class 2 Sharpie T.E.C or Action Marker GE Spec A50TF201 or MIL-T-5544

Marking Pen Thread Lubricant 5.

WP 216 00 WP 427 00





High Pressure Turbine Stage 1 Nozzle Removal. a.


b.

Remove HPT rotor (16, figure 1) and HPT rotor stage 2 nozzle assembly per WP 201 00.

c.

Using marking pen, matchmark HPT nozzle support to CRF aft flange.

d.

Remove HPT stage 1 nozzle from engine as follows: (1)

Using marking pen, matchmark following components prior to removal: (a) Bolt cover (7) to CRF seal support (8). (b) CRF baffle (10) to HPT stage 1 nozzle support (5). (c) CRF seal support (8) to HPT stage 1 nozzle support (5). (d) CRF seal support (8) to aft stationary air seal (11).

(2)

Remove 36 bolts (13) and self-locking nuts (12) that secure CRF seal support (8) to aft stationary air seal (11).

(3)

Remove 72 shear bolts (6) that secure CRF seal support (8) to HPT stage 1 nozzle support (5).

(4)

Remove bolt cover (7) from CRF seal support (8).

(5)

Remove CRF seal support (8) from engine by pulling straight aft out of engine.

(6)

Install lift fixture, 1C8217, onto HPT stage 1 nozzle support as follows: (a) Attach hoist to lift fixture, 1C8217, at lifteye (1, figure 2). (b) Remove quick-release pins (5 and 7) from lift arm (2). (c) Lower upper sliding arm (4) to inward stop. (d) Lift lower sliding arm (6) to inward stop.




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



Figure 2. Lift Fixture, 1C8217 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (e) Move lift fixture, 1C8217, forward to engage HPT stage 1 nozzle. (f) Engage upper fixed arm (3) and lower fixed arm (8) with bolt cover on HPT stage 1 nozzle. (g) Spread upper and lower sliding arm (4 and 6) outward to catch HPT stage 1 nozzle flange. (h) Engage quick-release pins (5 and 7) into lift arm (2) holes.

(7)

Remove 66 bolts (9, figure 1) that secure HPT stage 1 nozzle support (5) and CRF baffle (10) to CRF.

(8)

Remove CRF baffle (10) from HPT stage 1 nozzle support (5).

(9)

Install jackscrews, 1C6804, into threaded holes in bolt circle of HPT stage 1 nozzle support (5).

(10) Using jackscrews, 1C6804, separate HPT stage 1 nozzle assembly from CRF. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (11) Using lift fixture, 1C8217, remove HPT stage 1 nozzle assembly from CRF. (12) Remove jackscrews, 1C6804, from HPT stage 1 nozzle assembly once clear of CRF. CAUTION ENSURE FOREIGN OBJECTS DO NOT ENTER OR REMAIN IN AFT STATIONARY AIR SEAL INTERNAL CAVITY. FAILURE TO COMPLY CAN RESULT IN DAMAGE TO ENGINE. e.

Using barrier material, fabricate temporary cover to prevent entry of foreign objects into CRF.

f.

Insert temporary cover into CRF to seal stationary air seal internal cavity.

g.

Inspect HPT stage 1 nozzle per WP 427 00.




High Pressure Turbine Stage 1 Nozzle Installation. a.

Remove temporary cover, used to seal stationary air seal internal cavity, from CRF.

b.

If removed, install lift fixture, 1C8217, onto HPT stage 1 nozzle support (5, figure 1) per paragraph 6. step d. NOTE

c.

•

If reinstalling same components removed in paragraph 6., ensure matchmarks made during removal are aligned.

•

If installing different HPT stage 1 nozzle than was removed in paragraph 6., ensure HPT stage 1 nozzle borescope hole in CRF case aligns with HPT stage 1 nozzle borescope hole.

Install HPT stage 1 nozzle as follows: WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (1)

Using heat gun, heat forward flange of HPT stage 1 nozzle support (5). WARNING

WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY. (2)

Align HPT stage 1 nozzle support (5) boltholes with CRF case boltholes. Ensure HPT stage 1 nozzle inner and outer seals (4 and 2) engage fish mouth seals of combustor.

(3)

Install CRF baffle (10) onto HPT stage 1 nozzle support (5). Ensure CRF baffle properly engages aft stationary air seal.

(4)

Using thread lubricant, lightly coat threads and contact faces of 66 bolts (9).

(5)

Using 66 bolts (9), secure CRF baffle (10) and HPT stage 1 nozzle support (5) to CRF. Tighten bolts to 62-68 lb in. (7.0-7.6 N⋅m) of torque.

(6)

Install CRF seal support (8) onto aft stationary air seal (11) and HPT stage 1 nozzle support (5).




(7)

Using thread lubricant, lightly coat threads of 36 bolts (13), contact face of bolts, and 36 self-locking nuts (12) contact faces.

(8)

Using 36 bolts (13) and self-locking nuts (12), secure CRF seal support (8) to aft stationary air seal (11). Tighten bolts to 209-231 lb in. (23.7-26.1 N⋅m) of torque.

(9)

Using bolt cover (7) and 72 shear bolts (6), secure CRF seal support (8) to HPT stage 1 nozzle support (5). Tighten bolts to 55-70 lb in. (6.3-9.1 N⋅m) of torque.

d.

Using thread lubricant, coat washer (15) contact faces and borescope plug (14) threads.

e.

Install washer (15) and borescope plug (14) into HPT stage 1 nozzle borescope hole in CRF case. Tighten borescope plug to 300-330 lb in. (33.9-37.2 N⋅m) of torque and safety wire.

f.

Remove lift fixture, 1C8217, from HPT stage 1 nozzle support as follows:

g.

(1)

Remove quick-release pins (5 and 7, figure 2) from lift arm (2).

(2)

Lower upper sliding arm (4) to inward stop.

(3)

Lift lower sliding arm (6) to inward stop.

(4)

Move lift fixture, 1C8217, aft to disengage HPT stage 1 nozzle.

(5)

Spread upper and lower sliding arm (4 and 6) outward.

(6)

Engage quick-release pins (5 and 7) into lift arm (2) holes.

Install HPT rotor (16, figure 1) and HPT stage 2 nozzle assembly per WP 201 00.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE TURBINE ROTOR BLADE REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Turbine Rotor Stage 1 Blade Replacement............................................... High Pressure Turbine Rotor Stage 2 Blade Replacement...............................................

3 9


1

GEK 105054 Volume II WP 202 00 1.


Introduction. This work package provides instructions for the removal and installation of high pressure turbine rotor blades.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices High Pressure Turbine Rotor Replacement High Pressure Turbine Stage 2 Nozzle Assembly Replacement Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 201 00


Part No.

Program, Computer Airfoil Balancing Stock, Feeler Truck, HPT Rotor Transportation and Storage Program, Balance - Blade Installation/Replacement

BLADEOPT Local Purchase 2C6264G03 9446M61G01



Adhesive Marking Pen

GE Spec A50TF124B Sharpie T.E.C. or Action Marker Local Purchase

Shim Stock 5.

2

SWP 201 01 GEK 105055


IPB Figure No./Item

Ring Seal Stage 1 Damper Stage 2 Damper Bushings (as required) Ring Seal

22-5 22-10 22-21 22-4 22-5




High Pressure Turbine Rotor Stage 1 Blade Replacement. a.


b.

Remove high pressure turbine (HPT) rotor from engine per WP 201 00. Ensure HPT rotor is installed in HPT rotor transportation and storage truck, 2C6264G03.

c.

Remove HPT stage 2 nozzle from HPT rotor per SWP 201 01.

d.

Remove HPT rotor stage 1 blade as follows: (1)

Using marking pen, matchmark HPT rotor stage 1 blade retainer (1, figure 1) to HPT rotor forward shaft. Index clockwise, aft looking forward (ALF).

(2)

Using marking pen, matchmark 88 shear bolts (2) and 44 windage cups (3) as to HPT rotor location. Index clockwise, ALF.

(3)

Using marking pen, matchmark HPT rotor stage 1 blades (9) as to HPT rotor location. Index clockwise, ALF. CAUTION

•

THERE ARE 88 SHEAR BOLTS USED TO SECURE HPT ROTOR FORWARD SHAFT TO HPT ROTOR STAGE 1 DISK. REMOVE ONLY 44 SHEAR BOLTS USED TO SECURE HPT ROTOR STAGE 1 BLADE RETAINER TO HPT ROTOR STAGE 1 DISK OR DAMAGE TO ENGINE MAY OCCUR.

•

PENETRATING OIL WD40 SHALL NOT BE USED ON GAS GENERATOR OR GAS TURBINE. LIQUID WRENCH NO. 1 IS AN APPROVED SUBSTITUTE.

(4)

Using penetrating oil, lubricate 44 shear bolts (2) that secure HPT stage 1 blade retainer (1) to HPT rotor forward shaft (6). Allow penetrating oil to soak for 20 minutes, minimum.

(5)

Remove 44 shear bolts (2), 44 windage cups (3), and bushings (4) that secure HPT stage 1 blade retainer (1) to HPT rotor forward shaft (6).

(6)

Remove HPT rotor stage 1 blade retainer (1) from HPT rotor forward shaft (6).

(7)

Remove and discard two ring seals (5) from HPT rotor stage 1 blade retainer (1).


3



Figure 1. HPT Rotor-Stage 1 4




CAUTION HANDLE HPT ROTOR STAGE 1 BLADES WITH CARE. CONTAMINATION DUE TO IMPROPER HANDLING MAY CLOG AIR HOLES, RESULTING IN ENGINE DAMAGE. (8)

Remove HPT rotor stage 1 blade (9) by pushing blade forward. Store removed blades in approved container.

(9)

Using marking pen, matchmark 88 HPT rotor stage 1 seals (8) as to HPT rotor location. Index clockwise, ALF.

(10) Remove HPT rotor stage 1 seals (8) from HPT rotor stage 1 disk (7) dovetail. (11) Remove dampers (10) from HPT rotor stage 1 disk (7) dovetails. Discard dampers. e.

If all stage 1 blades will be replaced, calculate the blade positions with the blade installation/replacement balance program, 9446M61G01. CAUTION

f.

•

ENSURE HPT ROTOR STAGE 1 BLADE BEING INSTALLED DOES NOT EXCEED HEIGHT OF ADJACENT BLADES BY MORE THAN 0.003 INCH (0.07 MM) OR ENGINE DAMAGE SHALL OCCUR.

•

HPT ROTOR ASSEMBLY AND HPT STAGE 2 NOZZLE MAY BE A MATCHED SET. IF NEW HPT STAGE 2 ROTOR BLADES ARE BEING INSTALLED, ENSURE NEW BLADES ARE GROUND TO GIVE REQUIRED BLADE TIP-TO-SHROUD CLEARANCE.

Install HPT rotor stage 1 blade (9) as follows: CAUTION ENSURE HPT ROTOR STAGE 1 BLADES AND SEALS REMOVED FROM HPT ROTOR STAGE 1 DISK ARE REINSTALLED PER MATCHMARKED LOCATIONS OR HPT ROTOR IMBALANCE MAY OCCUR. (1)

Install damper (10) into pocket beneath HPT rotor stage 1 blade (9) platform.

(2)

Install HPT rotor stage 1 blade (9) into HPT rotor stage 1 disk (7) dovetail slot from forward side.


5



Larger end of HPT rotor stage 1 seal shall face forward.

g.

(3)

Install HPT rotor stage 1 seal (8) into HPT rotor stage 1 disk (7) from forward side.

(4)

Repeat steps (1) through (3) until all HPT rotor stage 1 blades (9) have been installed.

Check HPT rotor stage 1 blade installation (figure 2) as follows: (1)

Determine that damper (3) has perceivable movement with seal (4) and blade (5) fully installed.

(2)

Ensure that blade (5) has 0.010 inch (0.25 mm) minimum tip shake in circumferential direction.

(3)

Measure total accumulated gap (Dim J, View A) between HPT rotor stage 1 blade (5) pairs. (a) Dim J shall be 0.549 inch (13.94 mm) minimum for depth of Dim K (0.150 inch [3.81 mm]) per blade pair. (b) If Dim J does not meet requirements, replace either HPT rotor stage 1 blade (5) pair or HPT rotor stage 1 seal (4) between blade pair.

h.

If HPT rotor stage 1 blade retainer (1) is replaced, perform following: NOTE Bushings shall be thick enough that HPT rotor stage 1 blade retainer and HPT rotor stage 1 disk shall have a gap between them during trial fit. (1)

Install bushings (Detail C) of equal thickness as trial parts into 11 equally spaced locations on the aft side of the blade retainer. Record bushing thickness (Dim D). Dim D

(2)

Using 11 shear bolts with windage cups (3), temporarily secure HPT rotor blade retainer (1) onto HPT rotor stage 1 disk (2). Tighten shear bolts to 230 lb in (25.9 N•m).

(3)

Using feeler stock, measure clearance (Dim E) at each shear bolt locations. Divide by 11 to get the average clearance (Dim E). Dim E

6




Figure 2. HPT Rotor Blade Installation


7

GEK 105054 Volume II WP 202 00 (4)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines To determine actual clearance between HPT rotor stage 1 blade retainer (1) and HPT rotor stage 1 disk (2), take difference between Dim E and Dim D. Dim E - Dim D =

i.

(5)

Refer to IPB GEK 105055 to select appropriate bushings to provide an interference fit of 0.000-0.007 inch (0.00-0.18 mm) between the blade retainer and the disk.

(6)

Remove 11 shear bolts and windage cups (3) that secure HPT rotor stage 1 blade retainer (1) to HPT rotor stage 1 disk (2).

(7)

Remove HPT rotor stage 1 blade retainer (1) from HPT rotor stage 1 disk (2). Remove trial bushings.

Install HPT rotor stage 1 blade retainer (1, figure 1) as follows: (1)

Coat two ring seals (5) with adhesive to retain in place during HPT rotor stage 1 blade retainer (1) installation.

(2)

Install two ring seals (5) into grooves in aft side of HPT rotor stage 1 blade retainer (1).

(3)

If installing HPT rotor stage 1 blade retainer (1) previously removed, align matchmarks made during disassembly.

(4)

Using thread lubricant, coat bolt threads of 44 shear bolts (2) and contact faces of shear bolts and windage cups (3).

(5)

Install windage cups (3) onto shear bolts (2) per matchmarks made during disassembly.

(6)

Install bushings (4) into aft side of HPT rotor stage 1 blade retainer. NOTE

Preferred method of tightening shear bolts is torque plus rotation method. (7)

Install 44 shear bolts (2) through HPT rotor stage 1 blade retainer (1), HPT rotor forward shaft (6) and HPT rotor stage 1 disk (7) per matchmarks made during disassembly. Tighten shear bolts by either step (a) or (b) as follows: NOTE

Use locally manufactured shims (approximately 0.016 inch [0.40 mm]) between windage cup and blade retainer and windage cup and HPT forward shaft. this will prevent the windage cups from turning during torquing. (a) Tighten 44 shear bolts (2) to 219-241 lb in. (24.8-26.1 N⋅m) of torque. 8




(b) Tighten 44 shear bolts (2) to 60 lb in. (6.7 N⋅m) plus 92 to 96 degrees of wrench rotation. Torque shall be 240 lb in. (27.2 N⋅m) minimum and 330 lb in. (37.2 N⋅m) maximum. (8) 7.

Visually check fit of HPT rotor stage 1 blade retainer (1) to HPT rotor stage 1 seal (8) to verify that no gap exits.

High Pressure Turbine Rotor Stage 2 Blade Replacement. a.


b.

Remove high pressure turbine (HPT) rotor from engine per WP 201 00. Ensure HPT rotor is installed in HPT rotor transportation and storage truck, 2C6264.

c.

Remove HPT stage 2 nozzle from HPT rotor per SWP 201 01.

d.

Remove HPT rotor stage 2 blade as follows: (1)

Using marking pen, matchmark HPT rotor stage 2 blade retainer (10, figure 3) to HPT rotor stage 2 disk (5). Index clockwise, ALF.

(2)

Using marking pen, matchmark 90 shear bolts (12) and flat washers (11) as to HPT rotor location. Index clockwise, ALF.

(3)

Using marking pen, matchmark HPT rotor stage 2 blades (8) as to HPT rotor location. Index clockwise, ALF. CAUTION

PENETRATING OIL WD40 SHALL NOT BE USED ON GAS GENERATOR OR GAS TURBINE. LIQUID WRENCH NO. 1 IS AN APPROVED SUBSTITUTE. NOTE

•

To reduce chance of breaking shear bolts during loosening, tap lightly on bolthead while applying torque.

•

There are 90 shear bolts used to secure HPT rotor stage 2 disk to HPT rotor thermal shield. Thirty of these are used to secure HPT rotor stage 2 blade retainer to HPT rotor stage 2 disk.

(4)

Using penetrating oil, lubricate 30 shear bolts (12) that secure HPT stage 2 blade retainer (10) to HPT rotor stage 2 disk (5). Allow penetrating oil to soak for 20 minutes, minimum.

(5)

Remove 30 shear bolts (12) and flat washers (11) that secure HPT stage 2 blade retainer (10) to HPT rotor stage 2 disk (5).


9



Figure 3. HPT Rotor-Stage 2 10




Remove HPT rotor stage 2 blade retainer (10) from HPT rotor stage 2 disk (5).

(7)

Remove and discard ring seal (9) from HPT rotor stage 2 blade retainer (10). CAUTION

HANDLE HPT ROTOR STAGE 2 BLADES WITH CARE. CONTAMINATION DUE TO IMPROPER HANDLING MAY CLOG AIR HOLES, RESULTING IN ENGINE DAMAGE. (8)

Remove HPT rotor stage 2 blade (8) by pushing blade aft. Store removed blades in approved container.

(9)

Using marking pen, matchmark 90 HPT rotor stage 2 seals (6) as to HPT rotor location. Index clockwise, ALF.

(10) Remove HPT rotor stage 2 seals (6) from HPT rotor stage 2 disk (5) dovetail. (11) Remove dampers (7) from HPT rotor stage 2 disk (5) dovetails. Discard dampers. NOTE Blade installation/replacement balance program, 9470M55G01 covers replacement of all rotating airfoils (blades) from high pressure compressor to power turbine. e.

If weight of replacement HPT rotor stage 2 blade (8) is not the same as original blade, use blade installation/replacement balance program, 9446M61G01 computer program to replot blade locations.

f.

If all stage 2 blades will be replaced, calculate the blade positions with the blade installation/replacement balance program, 9446M61G01. CAUTION

•

Ensure HPT rotor stage 2 blade being installed does not exceed height of adjacent blades by more than 0.003 inch (0.07 mm) or engine damage shall occur.

•

HPT rotor assembly and HPT stage 2 nozzle may be a matched set. If new HPT stage 2 rotor blades are being installed, ensure new blades are ground to give required blade tip-to-shroud clearance.


11

GEK 105054 Volume II WP 202 00 g.


Install HPT rotor stage 2 blade (8) as follows: CAUTION ENSURE HPT ROTOR STAGE 2 BLADES AND SEALS REMOVED FROM HPT ROTOR STAGE 2 DISK ARE REINSTALLED PER MATCHMARKED LOCATIONS OR HPT ROTOR IMBALANCE MAY OCCUR. (1)

Install damper (7) into pocket beneath HPT rotor stage 2 blade (8) platform. Hook damper tabs into slot of blade. Apply a small amount of adhesive to hold damper in place during installation of blade. NOTE

Larger end of HPT rotor stage 2 seal shall face forward.

h.

(2)

Install HPT rotor stage 2 seal (6) into HPT rotor stage 2 disk (5) from aft side.

(3)

Install HPT rotor stage 2 blade (8) into HPT rotor stage 2 disk (5) dovetail slot from aft side.

(4)

Repeat steps (1) through (3) until all HPT rotor stage 2 blades (8) have been installed

Check HPT rotor stage 2 blade installation (figure 2) as follows: (1)

Check clearance AM (View B) as follows: (a) Squeeze adjacent blades together. (b) Move inner end of HPT rotor stage 2 seal (7) from side to side. (c) Slight movement of HPT rotor stage 2 seal (7) shall be felt. If no movement is felt, replace seal.

(2)

Measure total accumulated gap (Dim Q, View B) between HPT rotor stage 2 blade (6) pairs. (a) Dim Q shall be 0.549 inch (13.95 mm) minimum for depth of Dim K (0.150 inch [3.81 mm]) per blade pair. (b) If Dim Q does not meet requirements, replace either HPT rotor stage 2 blade (6) pair of HPT rotor stage 2 seal (7) between blade pair.

(3)

12

Ensure blades (6) have a minimum of 0.010 inch (0.25 mm) movement in circumferential direction.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines i.

Install HPT rotor stage 2 blade retainer (10, figure 3) as follows: (1)

Coat ring seal (9) with adhesive to retain in place during HPT rotor stage 2 blade retainer (10) installation.

(2)

Install ring seal (9) into groove in forward side of HPT rotor stage 2 blade retainer (10).

(3)

If installing HPT rotor stage 2 blade retainer (10) previously removed, align matchmarks made during disassembly.

(4)

Using thread lubricant, coat bolt threads of 30 shear bolts (12) and contact faces of shear bolts and 30 flat washers (11).

(5)

Install flat washers (11) onto shear bolts (12) per matchmarks made during disassembly. NOTE

Preferred method of tightening shear bolts is torque plus rotation method. (6)

Install 30 shear bolts (12) through HPT rotor stage 2 blade retainer (10), and HPT rotor stage 2 disk (5) per matchmarks made during disassembly. Tighten shear bolts by either step (a) or (b) as follows: (a) Tighten 30 shear bolts (12) to 83-92 lb in. (9.4-10.4 N⋅m) of torque. (b) Tighten 30 shear bolts (12) to 45 lb in. (5.1 N⋅m) plus 50 to 54 degrees of wrench rotation. Torque shall be 85 lb in. (9.6 N⋅m) minimum and 125 lb in. (14.1 N⋅m) maximum.

(7)

Visually check to ensure seal ring (9) has remained in place.

(8)

Visually check fit of HPT rotor stage 2 blade retainer (10) to HPT rotor stage 2 disk (5). Axial gap (dim. S) is not to exceed 0.004 inch (0.10 mm) with circumferential variation not to exceed 0.003 inch (0.08 mm).

Change 1

13/(14 Blank)




WORK PACKAGE

TECHNICAL PROCEDURES SINGLE ANNULAR COMBUSTOR REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Combustor Installation. ...................................................................................................... Combustor Removal. ...........................................................................................................

5 3


GEK 105054 Volume II WP 203 00 1.


Introduction. This work package contains instructions for removal and installation of the single annular combustor (SAC) combustion chamber.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Configuration Igniter Plug Replacement Gas Generator Outside Piping and Wiring Removal and Installation Gas Turbine Outside Piping and Wiring Removal and Installation Turbine Mid Frame Replacement High Pressure Turbine Rotor Replacement High Pressure Turbine Stage 1 Nozzle Assembly Replacement Gas Generator and Power Turbine Separation and Joining Combustor Inspection

GEK 105054 WP 002 00 WP 101 00 WP 103 00

SWP 113 01 WP 200 00 WP 201 00 SWP 201 02 WP 216 00 WP 425 00


Part No.

Fixture, Lift Combustion Liner, Horizontal Rod, Steel 0.400-0.407 in (10.17-10.33 mm) Dia

2C6066G03 Local Purchase



Marking Pen

Sharpie T.E.C. or Action Marker GE Spec A50TF54 736L680G01 R297P04 (Alt) GE Spec A50TF201 or MIL-T-5544

Penetrating Oil Safety Cable Safety Wire Thread Lubricant 5.

WP 113 00





Combustor Removal. a.


b.

Disconnect outside piping and wiring per WP 113 00 or SWP 113 01, as applicable.

c.

Separate gas generator and power turbine per WP 216 00 or packager’s manual.

d.


e.

Remove 30 fuel nozzles per WP 101 00.

f.

Remove high pressure turbine (HPT) rotor WP 201 00.

g.

Remove HPT stage 1 nozzle assembly per SWP 201 02.

h.

Remove igniter plugs or igniter plug and port plug per WP 103 00.

i.

Remove combustor from compressor rear frame (CRF) as follows: (1)

Attach hoist to combustor lift fixture, 2C6066, lift hook (1, figure 1). WARNING


Insert combustor lift fixture, 2C6066, into CRF.

(3)

Install combustor lift fixture, 2C6066, onto combustor (8) as follows: (a) Tilt and move combustor lift fixture, 2C6066, so bracket (5) and catch lip (6) engage fish mouth seal (7). (b) Using knob (4), move bracket (3) to catch fish mouth seal (7). Tighten knob finger-tight.

(4)

If same combustor is to be reinstalled, matchmark combustor to combustor lift fixture, 2C6066, vertical bar (2) using marking pen.

(5)

Using marking pen, number 10 combustor mounting pins and mounting bosses in CRF. Start at 12:00 o’clock position and index clockwise, aft looking forward.




Figure 1. Combustor Lift Fixture, 2C6066 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



PENETRATING OIL WD40 SHALL NOT BE USED ON GAS GENERATOR OR GAS TURBINE. LIQUID WRENCH NO. 1 IS AN APPROVED SUBSTITUTE.

j. 7.

(6)

Apply penetrating oil to 10 combustor mounting pins in CRF. Allow penetrating oil to soak for minimum of 10 minutes.

(7)

Remove safety wire and remove 10 combustor mounting pins from combustor and CRF.

(8)

Using hoist and combustor lift fixture, 2C6066, move combustor aft until clear of CRF.

Inspect combustor per WP 425 00.

Combustor Installation. a.

Install combustor into CRF as follows: (1)

If same combustor is to be reinstalled, align matchmarks on combustor and combustor lift fixture, 2C6066, vertical bar.

(2)

Attach hoist to combustor lift fixture, 2C6066, lift hook (1, figure 1). WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (3) Insert combustor lift fixture, 2C6066, and combustor into CRF. NOTE Ensure igniter openings in combustor and CRF are aligned during installation of combustor into CRF. (4)

Move combustor forward into CRF. Ensure forward cutouts in combustor align with CRF struts.

(5)

Apply thread lubricant to 10 combustor mounting pins.

(6)

Install 10 combustor mounting pins through CRF into combustor as follows: (a) Install pin 1 into CRF and combustor. Tighten mounting pin finger-tight. (b) Install pin 6 into CRF and combustor. Tighten mounting pin finger-tight. 5



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (c) Install pin 3 into CRF and combustor. Tighten mounting pin finger-tight. (d) Install pin 8 into CRF and combustor. Tighten mounting pin finger-tight. (e) Install pin 5 into CRF and combustor. Tighten mounting pin finger-tight. (f) Install pin 10 into CRF and combustor. Tighten mounting pin finger-tight. (g) Install pin 7 into CRF and combustor. Tighten mounting pin finger-tight. (h) Install pin 2 into CRF and combustor. Tighten mounting pin finger-tight. (i) Install pin 9 into CRF and combustor. Tighten mounting pin finger-tight. (j)

Install pin 4 into CRF and combustor. Tighten mounting pin finger-tight.

(7)

Insert steel rod through each borescope hole in CRF and combustor to verify proper alignment of combustor.

(8)

Final tighten 10 combustor mounting pins, following sequence from substep (6), to 300-360 lb in. (33.9-40.6 N⋅m) of torque.

(9)

Remove combustor lift fixture, 2C6066, from combustor as follows: (a) Loosen knob (4) and swing bracket (3) aft. (b) Tilt and move combustor lift fixture, 2C6066, aft so bracket (5) and catch lip (6) release fish mouth seal (7). (c) Remove combustor lift fixture, 2C6066, from CRF.

b.

Install igniter plugs or igniter plug and port plug per WP 103 00.

c.

Install HPT stage 1 nozzle assembly per SWP 201 02.

d.

Install HPT rotor WP 201 00.

e.

Install 30 fuel nozzles per WP 101 00.

f.

Using safety cable, safety-wire 10 combustor mounting pins.




g.


h.

Join gas generator and power turbine per WP 216 00 or packager’s manual.

i.

Connect outside piping and wiring per WP 113 00 or SWP 113 01, as applicable.




WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR INLET DUCT REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Gas Generator Inlet Duct Installation. .............................................................................. Gas Generator Inlet Duct Removal. ...................................................................................

3 3


GEK 105054 Volume II WP 204 00 1.


Introduction. This work package contains instructions for removal and installation of the gas generator inlet duct.

2.

3.


Number


GEK 105054 WP 002 00


Part No.

Sling, Nylon

Local Purchase

4.


5.





Gas Generator Inlet Duct Removal. a.


b.

Remove inlet screen (figure 1) per packager's manual.

c.

If installed, disconnect inlet plenum seal from bulkhead per packager's manual.

d.

If required, disconnect water wash inlet hose at connector located at 6:00 o'clock position on inlet duct per packager’s manual. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION INLET DUCT AND INLET PLENUM SEAL ASSEMBLY WEIGH APPROXIMATELY 82 LBS (37 KG). PROPERLY SUPPORT INLET DUCT AND SEAL ASSEMBLY WHILE REMOVING TO PREVENT DROPPING WITH SUBSEQUENT DAMAGE TO ASSEMBLY.

7.

e.

Wrap nylon sling around inlet duct forward of inlet plenum seal (if attached). Attach sling to hoist and adjust hoist to support weight of inlet duct.

f.

Remove 48 nuts and bolts that secure inlet duct to compressor front frame. Bag bracket attaching bolts separately from other bolts. Tag brackets for installation.

g.

Remove inlet plenum seal and seal retainers (if attached) from inlet duct. Retain seal and retainers for reinstallation.

Gas Generator Inlet Duct Installation. a.

Wrap nylon sling around inlet duct and attach sling to hoist. Lift inlet duct and plenum seal (if attached). Ensure water wash manifold connector is at 6:00 o'clock position.

b.

Move inlet duct and plenum seal (if attached) assembly into position onto compressor front frame (CFF). Align boltholes in inlet duct flange to boltholes in compressor front frame flange.

c.

Install 48 bolts, boltheads forward, and position brackets onto aft side of CFF flange. Install nuts and tighten to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

d.

If required, connect water wash inlet hose onto manifold connector per packager’s manual.

e.

Install inlet screen and inlet plenum seal per packager’s manual. 3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Inlet Duct Removal/Installation 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES CENTERBODY REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Centerbody Installation. ..................................................................................................... Centerbody Removal. ..........................................................................................................

3 3


GEK 105054 Volume II WP 205 00 1.


Introduction. This work package contains instructions for removal and installation of the centerbody.

2.


Number


GEK 105054 WP 002 00

3.


4.


5.

Nomenclature


Safety Cable Safety Wire Silicone Rubber Adhesive

736L680G01 R297P04 (Alt) GE Spec A15F6A3 (RTV 103) Black





Centerbody Removal. a.


b.

Remove inlet screen per packager’s manual. CAUTION AS SAFETY WIRE IS REMOVED, ENSURE ALL PIECES ARE ACCOUNTED FOR AND REMOVED, OR DAMAGE TO ENGINE MAY OCCUR.

7.

c.

Remove safety wire. Loosen, but do not remove, five bolts that secure centerbody (figure 1).

d.

Hold centerbody by hand and remove bolts. Retain bolts for installation of centerbody.

e.

Remove centerbody from compressor front frame (CFF).

Centerbody Installation. a.

Position centerbody onto CFF. Align boltholes. CAUTION AS SAFETY WIRE IS INSTALLED, ENSURE ALL CLIPPINGS ARE CAUGHT AND ACCOUNTED FOR, OR DAMAGE TO ENGINE MAY OCCUR.

b.

Hold centerbody by hand and install five bolts. Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. Safety-wire each bolt separately. Catch safety-wire clippings to prevent them from entering gas generator inlet. WARNING VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELLVENTILATED AREA.

c.

Apply silicone rubber adhesive to safety wire between bolthead and centerbody. Adhesive shall bond to centerbody at each location.

d.

Thoroughly inspect area prior to installing inlet screen. Account for all tools, parts, and other material brought into area.

e.

Install inlet screen per packager’s manual.




Figure 1. Centerbody Removal/Installation 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES ACCESSORY GEARBOX REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 10 ................. 0


Page

Accessory Gearbox Installation. ......................................................................................... Accessory Gearbox Removal. ..............................................................................................

5 4


GEK 105054 Volume II WP 206 00 1.


Introduction. This work package contains instructions for removal and installation of accessory gearbox (AGB) assembly.

2.

3.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Five Element Lube and Scavenge Pump Replacement Six Element Lube and Scavenge Pump Replacement Gas Generator Speed Sensor Replacement Lube Temperature Sensor Replacement Gas Generator Outside Piping and Wiring Removal and Installation Gas Turbine Outside Piping and Wiring Removal and Installation Fuel Pump Replacement Air/Oil Separator Replacement Pneumatic Starter (Shrouded/Non-Shrouded) Replacement Hydraulic Starter Replacement Hydraulic Pump Replacement Variable Stator Vane Servovalve Replacement Radial Drive Shaft Replacement Accessory Gearbox Inspection Illustrated Parts Breakdown

GEK 105054 Chapter 7 GEK 105054 WP 002 00 WP 102 00 SWP 102 01 WP 105 00 WP 110 00 WP 113 00 SWP 113 01 WP 115 00 WP 116 00 WP 117 00 SWP 117 01 WP 120 00 WP 121 00 WP 207 00 WP 420 00 GEK 105055


Part No.


1C5654G03 or 2C6301G02 1C6119G01

Guide, Expandable Bushing Jack, Fixture, Installation & Removal - Access Gearbox, Horizontal

1C6872G01






Dry Film Lubricant Lubricating Oil

GE Spec A50TF192 MIL-L-23699 or MIL-L-7808 736L680G01 R297P04 (Alt) Ge Spec A50TF201 or MIL-T-5544


5.

5.Expendable Material. Reference GEK 105055, Illustrated Parts Breakdown (IPB). Nomenclature

IPB Figure No./Item

Preformed Packing Preformed Packing

6-1 6-3


GEK 105054 Volume II WP 206 00 6.


Accessory Gearbox Removal. a.


b.

Disconnect all tubes, hoses, and electrical leads between AGB and gas generator per WP 113 00, or gas turbine per SWP 113 01.

c.

Disconnect lube system temperature sensor leads from sensors per WP 110 00.

d.

Remove radial driveshaft per WP 207 00.

e.

Remove any packager supplied tubing, wiring, and accessories per packager’s manual. NOTE If same AGB is to be reinstalled on engine, removal of components in steps f. through l. is optional.

f.

Remove five element lube and scavenge pump per WP 102 00 or six element lube and scavenge pump per SWP 102 01.

g.

Remove air/oil separator per WP 116 00.

h.

Remove pneumatic starter per WP 117 00, hydraulic starter per SWP 117 01, or packager supplied starter per packager’s manual.

i.

Remove fuel pump per WP 115 00 or packager’s manual, if applicable.

j.

Remove gas generator speed sensors per WP 105 00.

k.

Remove hydraulic pump per WP 120 00.

l.

Remove variable stator vane servovalve per WP 121 00.

m. Place AGB installation/removal fixture, 1C6872, onto lowering jack, 1C5654 or 2C6301. n.

Place AGB into AGB installation/removal fixture, 1C6872, as follows: (1)

Position lowering jack, 1C5654 or 2C6301, under AGB.



o.

7.


(2)

Raise lowering jack, 1C5654 or 2C6301, so AGB installation/removal fixture, 1C6872, pivot block (2, figure 1) contacts AGB (1).

(3)

Lock lowering jack, 1C5654 or 2C6301, floor locks to prevent movement of assembly.

(4)

Using adjusting rod (4), raise pivot block (3) until it contacts AGB (1). Tighten nut (5) hand-tight.

(5)

Using adjusting rod (6), raise support plate (7) until it contacts AGB (1). Tighten nut (5) hand-tight.

Remove AGB links from high pressure compressor (HPC) stator casing as follows: (1)

Remove bolt (12, figure 2), washer (2), and self-locking nut (3) that secure adjustable link (10) to mount (11).

(2)

Remove two bolts (1), washers (2), and self-locking nuts (3) that secure fixed link (9) and adjustable link (7) to mount (8).

(3)

Remove bolt, self-locking nut, and expandable bushing that secure transfer gearbox (TGB) mount to compressor front frame (CFF).

p.

Using lowering jack, 1C5654 or 2C6301, lower AGB installation/removal fixture, 1C6872, with AGB installed, away from HPC stator casing.

q.

Remove TGB wear-adapter sleeve from TGB. Remove and discard two preformed packings from TGB wear-adapter sleeve. Remove and discard preformed packing from TGB radial adapter assembly.

r.

Release lowering jack, 1C5654 or 2C6301, floor locks and move assembly away from engine.

s.

If desired, remove two bolts, washers, and self-locking nuts that secure adjustable links to AGB. Remove adjustable links.

t.

If desired, remove bolt, washer, and self-locking nut that secure fixed link to AGB. Remove fixed link.

u.

If desired, inspect AGB per WP 420 00.

Accessory Gearbox Installation. a.

Apply dry film lubricant to spherical bearings of adjustable links (7 and 10, figure 2) and fixed link (9) rod-end bearings.




Figure 1. AGB Installation/Removal Fixture, 1C6872 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



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

GEK 105054 Volume II WP 206 00 b.

c.


If required, assemble two adjustable links (7 and 10) as follows: (1)

Install nut (5) onto rod-end assembly (4).

(2)

Place locking device (6) onto rod-end assembly (4).

(3)

Install rod-end assembly (4) into adjustable link (7 and 10) mount with equal amount of (approximately seven) threads exposed at end of link mount. Nut (5) shall be torqued during radial drive shaft installation.

(4)

Repeat substeps (1) through (3) for remaining ends of adjustable link (7 and 10) mount assemblies.

If required, install adjustable links (7 and 10) and fixed link (9) onto AGB mounts as follows: CAUTION ENSURE FLANGED SLEEVE BUSHINGS ARE INSTALLED IN GEARBOX MOUNT CLEVIS PRIOR TO INSTALLATION OF LINK MOUNT ASSEMBLIES. (1)

Lightly coat threads of three bolts with thread lubricant.

(2)

Install fixed link (9) into middle AGB mount clevis.

(3)

Secure fixed link (9) to AGB mount clevis using bolt and bushing from right side, with washer and self-locking nut on left side. Tighten self-locking nut to 150-170 lb ft. (203-230 N⋅m) of torque.

(4)

Install short adjustable link (7) into right, aft looking forward, AGB mount clevis.

(5)

Using bolt from aft side, with washer and self-locking nut on forward side, secure link (7). Tighten self-locking nut to 150-170 lb ft. (203-230 N⋅m) of torque.

(6)

Install long adjustable link (10) into left, aft looking forward, AGB mount clevis.

(7)

Using bolt, from left side and washer and self-locking nut on right side, secure link (10). Tighten self-locking nut to 150-170 lb ft. (203-230 N⋅m) of torque.




WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. d.

Lubricate preformed packing with lubricating oil and install packing onto TGB radial adapter assembly.

e.

Lubricate preformed packing with lubricating oil and install onto TGB wearadapter sleeve. Install TGB wear-adapter sleeve onto TGB radial adapter assembly.

f.

Move lowering jack, 1C5654 or 2C6301, with AGB installation/removal fixture, 1C6872, and AGB installed under engine. CAUTION USE CARE WHEN RAISING AND ALIGNING AGB TO AVOID DAMAGE TO PREFORMED PACKING INSTALLED ON TGB WEAR-ADAPTER SLEEVE.

g.

Carefully raise lowering jack, 1C5654 or 2C6301, so TGB wear-adapter sleeve slips into CFF opening and bottoms in CFF radial drive shaft bore. Lock lowering jack floor jacks.

h.

Align AGB adjustable links (7 and 10) and fixed link (9) with mounts (8 and 11) on HPC stator casing.

i.

Lightly coat bolt threads of two bolts (1 and 12) with thread lubricant.

j.

Install bolt (12), bolthead aft, with washer (2), and self-locking nut (3) on forward side through rod-end assembly (4) of adjustable link (10) and HPC stator casing mounts (8 and 11). Tighten self-locking nut to 150-170 lb ft. (203-230 N⋅m) of torque.

k.

Install bolt (1), bolthead forward, with washer (2), and self-locking nut (3) on aft side through rod-end assembly (4) of fixed link (9) and HPC stator casing mount (8). Tighten self-locking nut to 150-170 lb ft. (203-230 N⋅m) of torque.

l.

Connect adjustable link (7) to HPC stator case mount (8) installing bolt (1) from forward side with washer and self-locking nut on aft side. Tighten self-locking nut to 150-170 lb ft. (203-230 N⋅m) of torque.

m. Secure TGB mounting bracket to CFF as follows: (1)

Screw bushing guide, 1C6119, onto expandable bushing/bolt by hand until it bottoms. Do not apply pressure that could expand bushing.




(2)

Insert bushing guide, 1C6119, into TGB mounting bracket (bolthead to left, aft looking forward). If necessary, lightly tap bolthead with plastic mallet to align TGB mounting bracket to CFF strut.

(3)

Remove bushing guide, 1C6119, after expandable bushing is installed.

(4)

Install shear bolt through expandable bushing and secure with self-locking nut. Tighten self-locking nut to 123-135 lb ft (166.8-183.0 N⋅m) of torque.

n.

Using lowering jack, 1C5654 or 2C6301, lower AGB installation/removal fixture, 1C6872, away from AGB.

o.

Release lowering jack, 1C5654 or 2C6301, floor locks and move assembly away from engine.

p.

Install radial driveshaft per WP 207 00.

q.

If removed, install variable stator vane servovalve per WP 121 00.

r.

If removed, install hydraulic pump per WP 120 00.

s.

If removed, install gas generator speed sensors per WP 105 00.

t.

If removed, install fuel pump per WP 115 00 or packager’s manual.

u.

If removed, install pneumatic starter per WP 117 00, hydraulic starter per SWP 117 01, or packager supplied starter per packager’s manual.

v.

If removed, install air/oil separator per WP 116 00. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

w.

If removed, install five element lube and scavenge pump per WP 102 00 or six element lube and scavenge pump per SWP 102 01.

x.

Connect all tubes, hoses, and electrical leads between accessory gearbox (AGB) and gas generator per WP 113 00, or gas turbine per SWP 113 01.

y.

Connect lube system temperature sensor leads from sensors per WP 110 00.

z.

Connect any packager supplied tubing, wiring, and accessories per packager’s manual.

aa. Motor engine per GEK 105054, Chapter 7. ab. Check all fluid connections for leakage. 10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES RADIAL DRIVE SHAFT REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Radial Drive Shaft Installation. ......................................................................................... Radial Drive Shaft Removal. ..............................................................................................

5 3


GEK 105054 Volume II WP 207 00 1.


Introduction. This work package provides instructions for the removal and installation of the radial drive shaft.

2.

3.

4.


Number


GEK 105054 WP 002 00 GEK 105055


Part No.

Tool Set, Radial Drive Shaft Tool Set, Jackscrew - Disassemble Flanges

1C6361G01 1C6804G04



Lubricating Oil




IPB Figure No./Item

Preformed Packing Retaining Ring Preformed Packing Preformed Packing

6-5 6-4 8-3 8-96




Radial Drive Shaft Removal. a.


b.

Place approved waste container under accessory gearbox (AGB) drain. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

c.

Remove safety wire and remove drain plug (19, figure 1) and drain oil. Remove and discard preformed packing from drain plug.

d.

Remove two nuts and washers that secure access cover plate (18) to bottom of transfer gearbox (TGB).

e.

Using jackscrews, 1C6804, carefully remove TGB access cover plate (18) and preformed packing. Discard preformed packing.

f.

Remove retaining ring (17), located at bottom of radial drive shaft spacer (14), inside TGB. Using screwdriver, unwind retaining ring. Discard retaining ring.

g.

Turn tool, 1C6361, hand nut (6) toward T-handle of rod (7) until no threads are visible at end of rod between hand nut and T-handle.

h.

Place sleeve (5) on rod (7) against hand nut (6).

i.

Install washer (2), expandable plug (3), and washer (4) onto socket head screw (1).

j.

Install socket head screw into end of rod (7), finger-tight. Lightly turn hand nut (6) until snug against sleeve (5).

k.

Insert tool, 1C6361, into TGB access hole.

l.

Raise tool, 1C6361, as far as it can go and insert expandable plug (3) through center of radial drive shaft spacer (14).

m. Hold T-handle of rod (7) and turn hand nut (6) to expand expandable plug (3).




Figure 1. Radial Drive Shaft Removal/Installation 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION RADIAL DRIVE SHAFT MAY SUDDENLY DROP OUT AFTER REMOVAL OF SPACER. HAND SHOULD BE HELD UNDER OPENING TO PREVENT DRIVE SHAFT FROM FALLING OUT OF GEARBOX. NOTE Radial drive shaft (12) may be lowered with radial drive shaft spacer (14). n.

Pull down on tool, 1C6361, to remove radial drive shaft spacer (14) and radial drive shaft (12), if radial drive shaft is lowered with spacer.

o.

If radial drive shaft (12) comes out with radial drive shaft spacer (14), grasp radial drive shaft by hand and remove it. If radial drive shaft remains in compressor front frame (CFF) strut and TGB, hold hand under TGB access opening.

p.

Loosen hand nut (6) and remove radial drive shaft spacer (14) from tool, 1C6361.

q.

Remove and discard preformed packing (15). NOTE If radial drive shaft (12) has been removed during removal of radial drive shaft spacer (14), disregard following steps.

7.

r.

Remove socket head screw (1), expandable plug (3), and washers (2 and 4) from tool, 1C6361.

s.

Install collet (8) and draw screw (9) into end of tool, 1C6361. Finger-tighten draw screw snug into collet.

t.

Insert collet-end of tool, 1C6361, into radial drive shaft (12). Hold T-handle and turn hand nut (6) to expand collet (8).

u.

Pull down on tool, 1C6361, and remove radial drive shaft (12) from gearbox.

v.

Loosen hand nut (6) and remove radial drive shaft (12) from tool, 1C6361.

Radial Drive Shaft Installation. a.

Place tool, 1C6361, sleeve (5, figure 1) onto rod (7) against hand nut (6).

b.

Install washer (2), expandable plug (3), and washer (4) onto socket head screw (1).

c.

Install screw into end of rod (7), finger-tight.




LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. d.

Lubricate new preformed packing (15) with lubricating oil and install onto OD of radial drive shaft spacer (14).

e.

Place expandable end of tool, 1C6361, into preformed packing end of radial drive shaft spacer (14).

f.

Hold T-handle of rod (7) and tighten hand nut (6) to secure radial drive shaft spacer onto expandable plug (3).

g.

Place shear section (grooved) end of radial drive shaft (12) up through TGB access hole. Raise radial drive shaft and support by hand.

h.

Insert radial drive shaft spacer (14) and tool, 1C6361, into bottom end of radial drive shaft (12).

i.

Raise radial drive shaft (12), radial drive shaft spacer (14), and tool, 1C6361, into TGB access hole and CFF strut as far as possible.

j.

Engage radial drive shaft splines, turning radial drive shaft slightly, if necessary. Apply medium pressure to engage spacer preformed packing (15).

k.

Move radial drive shaft (12) and radial drive shaft spacer (14) up and down, to ensure no binding exists. Adjust turnbuckles of AGB mounting links, as required, to relieve binding. CAUTION SPACER AND DRIVE SHAFT ARE RETAINED ONLY BY SNUG FIT OF SPACER PREFORMED PACKING. IF PREFORMED PACKING IS NOT ENGAGED, SPACER AND SHAFT MAY DROP OUT, CAUSING DAMAGE.

l.

Hold T-handle on bottom of rod (7) and loosen hand nut (6) to disengage expandable plug (3) from radial drive shaft spacer (14). Carefully remove tool, 1C6361.

m. Insert finger at bottom of radial drive shaft spacer (14) to ensure spacer is raised high enough to expose retaining ring groove (16). n.

Place new retaining ring (17) onto flanged end of retaining ring shaft (11).




o.

Using retaining ring pusher (10), push retaining ring (17) into retaining ring shaft (11), until retaining ring is 0.125-0.250 inch (3.2 to 6.3 mm) from narrow end of shaft. Align cutout sections of shaft and pusher.

p.

Turn retaining ring shaft (11) cutouts to face aft and place shaft up against bevel gear (13).

q.

Push retaining ring shaft (11) up as far as possible. Hold in place with upward pressure.

r.

Push retaining ring pusher (10) up as far as it can go to position retaining ring (17) into retaining ring groove (16) under radial drive shaft spacer (14). CAUTION IMPROPERLY INSTALLED RETAINING RING CAN CAUSE RADIAL DRIVE SHAFT FAILURE AND GAS GENERATOR SHUTDOWN.

s.

Insert finger through opening and ensure retaining ring (17) is properly installed into retaining ring groove (16).

t.

Install rod (7) and expandable plug (3) into radial drive shaft spacer (14). Hand-tighten hand nut (6). CAUTION RADIAL DRIVE SHAFT SHALL BE ABLE TO MOVE FREELY ALONG AXIS WITHIN LIMITS IMPOSED BY RETAINING RINGS, OR DAMAGE MAY OCCUR.

u.

Pull rod (7) down to seat radial drive shaft spacer (14) against retaining ring (17). Check to ensure radial drive shaft (12) can move freely. If required, adjust radial drive shaft positioning as follows: (1)

If necessary, adjust turnbuckles of AGB mounting links.

(2)

After adjustment, check to ensure No. 56 drill (0.055 inch [1.39 mm] diameter) shall not pass through witness hole in each end of turnbuckles.

v.

Tighten jamnuts on AGB mounting links to 100 lb in. (11.3 N⋅m) of torque and safety-wire.

w.

Loosen hand nut (6) and remove tool, 1C6361.




LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. x.

Lubricate new preformed packing with lubricating oil and install onto TGB access cover plate (18).

y.

Install TGB access cover plate onto bottom of TGB and secure with two nuts and washers. Tighten nuts to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

z.

Lubricate new preformed packing with lubricating oil and install onto drain plug (19). Install drain plug into AGB. Tighten drain plug to 60-80 lb in. (6.8-9.0 N⋅m) of torque. Safety-wire drain plug.




WORK PACKAGE

TECHNICAL PROCEDURES INLET GEARBOX REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Inlet Gearbox Installation. ................................................................................................. Inlet Gearbox Removal........................................................................................................

5 3


GEK 105054 Volume II WP 208 00 1.


Introduction. This work package provides instructions for the removal and installation of the inlet gearbox (IGB).

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Centerbody Replacement Radial Drive Shaft Replacement Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 205 00 WP 207 00 GEK 105055


Part No.

Protector, Strut Cavity - Compressor Front Frame Mallet, Soft Plastic

1C8099P01 Local Purchase



Dry Ice Isopropyl Alcohol Lint-Free Cloth Lubricating Oil

Fed Spec BB-C-104 Fed Spec TT-I-735 Local Purchase MIL-PRF-23699 or MIL-PRF-7808 Sharpie T.E.C. or Action Marker Local Purchase 736L680G01 R297P04 (Alt)

Marking Pen Plastic Bag Safety Cable Safety Wire 5.


IPB Figure No./Item

Gasket Preformed Packing Preformed Packing Preformed Packing

3-27 3-3 3-30 3-35




Inlet Gearbox Removal. a.


b.

Remove radial drive shaft per WP 207 00.

c.

Remove centerbody per WP 205 00.

d.

Remove 10 bolts (20, figure 1) that secure sump cover (2) to compressor front frame (CFF) (9). Retain bolts for installation.

e.

Remove and discard preformed packing (1) from sump cover (2). WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

f.

Using lint-free cloth and isopropyl alcohol, clean area around 6:00 o'clock position opening inside CFF (9).

g.

Using strut cavity protector, 1C8099 (13), seal radial drive shaft opening in CFF strut to prevent foreign material from entering CFF strut.

h.

Remove two bolts (15) and self-locking nuts (14) that secure No. 3 damper bearing oil supply tube (7) and oil supply tube (5) to gearbox oil pad (8) at 4:00 o’clock position. Retain bolts and self-locking nuts.

i.

Remove two bolts (16) and flat washers (17) that secure No. 3 damper bearing oil supply tube (7) to aft flange of IGB (10). Retain No. 3 damper bearing oil supply tube, flat washers, and bolts. Remove and discard gasket (4) and preformed packing on No. 3 damper bearing oil supply tube. CAUTION THERE ARE 25 BOLTS IN AFT FLANGE OF IGB; 12 BOLTS (16 AND 18) SECURE IGB TO CFF AND 13 BOLTS INSTALLED IN CLEARANCE HOLES. DO NOT LOOSEN ANY BOLTS IN CLEARANCE HOLES; THESE SECURE NO. 3 BEARING. MAJOR ENGINE DAMAGE SHALL OCCUR IF BOLTS IN CLEARANCE HOLES ARE LOOSENED.

j.

Using standard wrench and extension, loosen 10 bolts (18) and flat washers (19) that secure IGB mounting flange (12) to CFF (9).




Figure 1. IGB Removal/Installation 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE IGB weighs about 38 pounds (17 kg). Two people may be required to handle IGB during removal. k.

Support IGB (10) by hand and completely remove 10 bolts (18) and flat washers (19) from IGB mounting flange (12). NOTE It may be necessary to lightly tap IGB housing with soft mallet while pulling forward to disengage shaft splines.

l.

Remove IGB (10) from high pressure compressor (HPC) rotor front shaft (11) by pulling IGB straight forward from CFF.

m. Remove and discard preformed packing (3) from oil supply tube located inside CFF at 4:00 o'clock position (forward looking aft). 7.

Inlet Gearbox Installation. a.

Thoroughly inspect sump area inside CFF (9, figure 1). Ensure area is free of all foreign material. WARNING LUBRICATING OIL, MIL-PRF-23699 OR MIL-PRF-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Lubricate preformed packing (3) with lubricating oil, and install onto oil supply tube located inside CFF at 4:00 o'clock position.

c.

Use depth micrometer and parallel bar to measure drop A from sump cover flange to IGB mounting flange (12) at 12:00 o’clock, 4:00 o’clock, and 8:00 o’clock positions. Using marking pen, mark three bolthole locations where drops are taken and record drop values by location. Drop A: 12:00

d.

4:00

8:00

Use OD micrometer to measure drop B from IGB bearing cover to IGB mounting flange (12). Take measurements at boltholes corresponding to boltholes where drop A measurements were taken. Record values at each location. Drop B: 12:00

4:00

8:00




Calculate and record drop C (C = A - B). Calculate and record calculated drop C for each location. 4:00

Drop C: 12:00

8:00

WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. f.

Using isopropyl alcohol and lint-free cloth, clean splines of HPC rotor front shaft (11) and IGB shaft. Wipe off excess isopropyl alcohol. WARNING LUBRICATING OIL, MIL-PRF-23699 OR MIL-PRF-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

g.

Using lubricating oil, lightly coat HPC front shaft (11) splines.

h.

Inspect oil supply tube (5) mounting pad at CFF. Ensure four bolts are tight and safety-wired.

i.

Check for presence of radial drive shaft upper retaining ring inside IGB. If upper retaining ring is not present, install as follows: (1)

Compress upper retaining ring.

(2)

Insert upper retaining ring into radial drive shaft opening.

(3)

Using hand pressure only, seat upper retaining ring into IGB. WARNING

LUBRICATING OIL, MIL-PRF-23699 OR MIL-PRF-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. j.

Apply thin coating of lubricating oil to overall surface of IGB (10).



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW-TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. CAUTION ENSURE IGB IS COMPLETELY ENCASED IN PLASTIC AND NO METAL SURFACES ARE EXPOSED TO DRY ICE OR MOISTURE. k.

Place IGB (10) into clean plastic bag and seal bag. Chill in dry ice for minimum of 20 minutes. WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING COLD PARTS.

l.

Remove IGB (10) from dry ice and from plastic bag.

m. Position IGB (10) so dowel pin in aft flange is at approximately 7:00 o'clock position (forward looking aft). n.

Carefully place IGB (10) into CFF (9), align dowel pin to hole in CFF mounting flange, and align oil pad (8) to oil supply tube (5). CAUTION DO NOT USE EXCESSIVE FORCE TO SEAT IGB AS SPLINE DAMAGE COULD RESULT.

o.

Align splines of IGB shaft with splines of HPC rotor front shaft (11).

p.

Carefully seat IGB (10) onto IGB mounting flange (12). Ensure oil supply tube (5) engages IGB oil pad (8) properly. Visually inspect to ensure IGB mounting flange is properly seated. NOTE Do not install bolts (16) on either side of No. 3 damper bearing oil supply port at this time.

q.

Using socket and extension, install 10 bolts (18) and flat washers (19) used to secure IGB to CFF. Tighten bolts to 62-68 lb in. (7.0-7.6 N⋅m) of torque using crisscross pattern.


GEK 105054 Volume II WP 208 00 r.


Measure actual drop C from sump cover flange to forward face of IGB at each marked location. Drop C: 12:00

4:00

8:00

(1)

Compare each actual drop C with corresponding calculated drop C.

(2)

Measured drop shall be within 0.002 inch (0.05 mm) of calculated drop at each location.

(3)

If drop does not meet limits, remove IGB (10), inspect for dirt, high metal, etc., and repeat installation procedure, including drop checks. WARNING

LUBRICATING OIL, MIL-PRF-23699 OR MIL-PRF-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. s.

Lubricate preformed packing with lubricating oil and install onto aft end of No. 3 damper bearing oil supply tube (7).

t.

Install No. 3 damper bearing oil supply tube (7) onto IGB mounting flange (12) as follows:

u.

(1)

Align No. 3 damper bearing oil supply tube (7) aft mounting flange with holes in IGB mounting flange (12).

(2)

Using two bolts (16) and flat washers (17), secure No. 3 damper bearing oil supply tube (7) to IGB mounting flange (12). Tighten bolts to 62-68 lb in. (7.0-7.6 N⋅m) of torque.

Using two bolts (15) and self-locking nuts (14), secure gasket (4) and No. 3 damper bearing oil supply tube (7) to oil pad (8). Tighten bolts to 62-68 lb in. (7.0-7.6 N⋅m) of torque. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

v.

Ensure sump area is free of all foreign material. Using lint-free cloth and isopropyl alcohol, clean sump cover (2) and sump cover mounting flange on CFF.




CAUTION ENSURE STRUT CAVITY PROTECTOR, 1C8099, IS REMOVED FROM CFF STRUT PRIOR TO RADIAL DRIVE SHAFT INSTALLATION TO AVOID DAMAGE TO ENGINE. w.

Remove strut cavity protector, 1C8099 (13), from radial drive shaft opening in CFF strut. WARNING LUBRICATING OIL, MIL-PRF-23699 OR MIL-PRF-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

x.

Apply thin coating of lubricating oil to preformed packing (1). Install lubricated preformed packing in groove of sump cover (2).

y.

Position sump cover (2) onto front flange of CFF (9). Align boltholes and install 10 bolts (20). Tighten bolts to 62-68 lb in. (7.0-7.6 N⋅m) of torque.

z.

Install radial drive shaft per WP 207 00.

aa. Install centerbody per WP 205 00.




WORK PACKAGE

TECHNICAL PROCEDURES VARIABLE STATOR VANE MECHANISM REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Page

Variable Stator Vane Mechanism Installation. ................................................................. 13 Variable Stator Vane Mechanism Removal. ...................................................................... 3


GEK 105054 Volume II WP 209 00 1.


Introduction. This work package provides instructions for the removal and installation of the connector links, actuation ring segments, and actuation arms used to activate the variable stator vane (VSV) system.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Variable Stator Vane Actuator Replacement Gas Generator Outside Piping and Wiring Removal and Installation Gas Turbine Outside Piping and Wiring Removal and Installation High Pressure Variable Stator Vane Torque Shaft Replacement High Pressure Compressor Stator Casings Replacement Variable Stator Vane System Inspection Hydraulic Pump Replacement

GEK 105054 Chapter 7 GEK 105054 WP 002 00 WP 100 00

SWP 113 01 WP 114 00 WP 211 00 WP 418 00 WP 120 00


Part No.

Assembly, Hydraulic Actuator Unit Holder Set, Variable Stator Vanes

1C3569G2/G3 1C8324G01



Lubricating Oil

MIL-L-23699 or MIL-L-7808 Sharpie T.E.C. or Action Marker Local Purchase

Marking Pen Masking Tape 5.

WP 113 00





Variable Stator Vane Mechanism Removal. a.


b.

Move VSV system to full open position as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Disconnect VSV actuators rod-end and head-end hoses. Drain residual lubricating oil into approved waste container. CAUTION

(2)

•

Use hydraulic actuator unit, 1C3569G3, with engines that use lubricating oil, MIL-L-23699.

•


•

Do not intermix lubricating oils, MIL-L-7808 and MIL-L-23699.

Connect hydraulic actuator unit, 1C3569, to VSV actuators rod-end and head-end ports. WARNING

SERIOUS INJURY CAN OCCUR WHEN APPLYING HYDRAULIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS. (3)

Using hydraulic actuator unit, 1C3569, move VSV actuators to full open position.

(4)

Disconnect hydraulic actuator unit, 1C3569, from VSV actuators.

c.

Remove two VSV actuators from engine per WP 100 00.

d.

Remove two VSV torque shafts from engine per WP 114 00.




There are a total of 16 connector links, eight each side, on engine. Removal procedure is same for all. e.

Remove connector links (4, figure 1) from actuation ring segments as follows: (1)

Using marking pen, position mark connector link engine location.

(2)

Remove four bolts (2) and flat washers (3) from connector link (4).

(3)

Remove connector link (4) from actuation ring segments (5). Remove two straight pins (1) from connector link.

(4)

Repeat steps (1) through (3) for all applicable connector links. NOTE

Inlet guide vane (IGV) actuation ring segments are not held against high pressure compressor (HPC) stator casing by VSV actuation arms. All IGV actuation arm pins face radially outward. f.

Remove IGV actuation ring segments from HPC stator case. Using masking tape, secure actuation arm sleeves (31, figure 2) to IGV actuation ring segments.

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



Remove outside piping, tubing, and wiring, as required for HPC stator casing removal, per WP 113 00 or SWP 113 01.

h.

Remove HPC stator casings per WP 211 00. NOTE

i.

•

There are two stage 0 actuation ring segments, one on each HPC stator casing half. Removal procedure is same for both.

•

Stage 0 actuation arms (10) located on horizontal split-line of HPC stator casing (20) have pins facing radially outwards. All other stage 0 actuation arms (19) have pins facing radially inward.

Remove stage 0 actuation ring segment from HPC stator casing (20) as follows: (1)

Install VSV holder, 1C8324P03, onto stage 0 vane.

(2)

Loosen self-locking nuts (17) from stage 0 stator vane (2).

(3)

Pull up gently on pin end of stage 0 actuation arm (19) until pin disengages from actuation ring segment.

(4)

Turn stage 0 actuation arm (19) so that actuation arm is clear of actuation ring segment.

(5)

Repeat steps (1) through (4) for remaining 17 stage 0 actuation arms.

(6)

Using masking tape, secure actuation arm sleeves (31) to stage 0 actuation ring segment.

(7)

Using marking pen, position mark stage 0 actuation ring segment with engine location.

(8)

Remove stage 0 actuation ring segment from HPC stator casing (20). NOTE

j.

•


•







Figure 2. VSV Actuation Components (Sheet 1 of 3) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.










(3)


(4)


(5)


(6)


(7)


(8)


k.

•


•




(2)


(3)


(4)


(5)


(6)


(7)


(8)

Remove stage 2 actuation ring segment from HPC stator casing (20).




l.

•


•




(2)


(3)


(4)


(5)


(6)


(7)


(8)


•


•

Two stage 4 actuation arms (14) located on horizontal split-line of HPC stator casing (20) have pins facing radially outwards. All other stage 4 actuation arms (28) have pins facing radially inward.

m. Remove stage 4 actuation ring segment from HPC stator casing (20) as follows: (1)


(2)


(3)






(5)


(6)


(7)


(8)


n.

•


•




(2)


(3)


(4)


(5)


(6)


(7)


(8)





o.

p.

•


•




(2)


(3)


(4)


(5)


(6)


(7)


(8)


If any VSV actuation arms on any stage are distorted, bent, or damaged, proceed as follows: (1)

Inspect VSV system for damage or indications of binding per WP 418 00. CAUTION

TEMPORARILY SECURE VSV VANE PRIOR TO REMOVING SECURING HARDWARE FROM VSV VANE, OR DAMAGE DUE TO DROPPING MAY OCCUR. (2)

If VSV stages IGV through 4 actuation arms are damaged, proceed as follows: (a) Remove self-locking nut (17) from VSV vane (8). (b) Remove sleeve (24) from VSV vane.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (c) Remove and replace VSV actuation arm. (d) Reinstall sleeve (24) onto VSV vane. (e) Inspect self-locking nut (17) for serviceability, replace as required. (f) Install appropriate VSV holder, 1C8324, onto vane.

(g) Install self-locking nut (17) onto VSV vane. Leave self-locking nut loose on VSV vane. (3)

If VSV stages 5 and 6 actuation arms are damaged, proceed as follows: (a) Remove self-locking nut (17) from VSV vane. (b) Remove and replace VSV actuation arm. (c) Inspect self-locking nut (17) for serviceability, replace as required. (d) Install appropriate VSV holder, 1C8324, onto vane. (e) Install self-locking nut (17) onto VSV vane. Leave self-locking nut loose on VSV vane.

7.

Variable Stator Vane Mechanism Installation. NOTE

a.

•

There are two stage 6 actuation ring segments, one on each HPC stator casing half. Installation procedure is same for both.

•

Two stage 6 actuation arms (16, figure 2) located on horizontal split-line of HPC stator casing (20) have pins facing radially outwards. All other stage 6 actuation arms (30) have pins facing radially inward.

Install stage 6 actuation ring segment onto HPC stator casing (20) as follows: (1)

Align stage 6 actuation ring segment onto HPC stator case (20) per position mark on actuation ring segment.

(2)

Remove masking tape used to secure actuation arm sleeves (31) to stage 6 actuation ring segment.

(3)

Pull up gently on pin end of stage 6 actuation arm (30) until pin clears actuation ring segment.




(4)

Turn stage 6 actuation arm (30) so that actuation arm pin is aligned with hole in actuation ring segment.

(5)

Engage stage 6 actuation arm (30) pin in actuation ring segment.

(6)

Tighten self-locking nuts (17) onto stage 6 stator vane (8) as follows: (a) Install VSV holder, 1C8324P09, onto stage 6 vane. (b) Tighten self-locking nut (17) to 86-94 lb in. (9.7-10.6 N⋅m) of torque.

(7)

Repeat steps (3) through (6) for remaining 27 stage 6 actuation arms. NOTE

b.

•


•




(2)


(3)


(4)


(5)


(6)


(7)





c.

•


•




(2)


(3)


(4)


(5)


(6)


(7)


d.

•


•







(2)


(3)


(4)


(5)


(6)


(7)


e.

•


•




(2)


(3)


(4)


(5)


(6)






f.

•


•




(2)


(3)


(4)


(5)


(6)


(7)





g.

•


•




(2)


(3)


(4)


(5)


(6)


(7)


Inlet guide vane (IGV) actuation ring segments are not held against HPC stator casing by VSV actuation arms. All IGV actuation arm pins face radially outward. h.

Remove masking tape used to secure actuation arm sleeves (31) to actuation ring segment. Install actuation ring segment onto IGV actuation arms.

i.

Check VSV actuation torque relative to stator vane axis by pull test as follows: (1)

For stages IGV through stage 4, apply torque to move actuation ring segments +/- 5 degrees in open and closed direction. Torque shall be no greater than 140 lb in. (15.8 N⋅m) of torque.




For stages 5 and 6, apply torque to move actuation ring segments +/- 5 degrees in open and closed direction. Torque shall be no greater than 204 lb in. (23.0 N⋅m) of torque.

j.

Move all VSV stages to full open position.

k.

Install HPC stator casings onto engine per WP 211 00. NOTE There are 64 actuation ring spacers. Inspection and adjustment procedure is same for all.

l.

Inspect actuation ring spacers (5, figure 3) as follows: (1)

Using feeler gage, measure dim A. Dim A shall meet clearance requirements of table 1.

(2)

If dimension A does not meet table 1 clearance requirements, proceed as follows: (a) Loosen self-locking nut (1). (b) Using Allen wrench, adjust actuation ring spacer (5) clearance as required. (c) Using Allen wrench, apply countertorque to actuation ring spacer (5). Tighten self-locking nut (1) to 76-84 lb in. (8.6-9.4 N⋅m) of torque.




Figure 3. Actuation Ring Spacer Clearance Table 1. Actuation Ring Spacer Clearance (Dim A) Minimum

Maximum

Stage

Inches

(MM)

Inches

(MM)

IGV

0.002

0.051

0.004

0.101

0

0.002

0.051

0.004

0.101

1

0.002

0.051

0.004

0.101

2

0.002

0.051

0.004

0.101

3

0.002

0.051

0.004

0.101

4

0.005

0.127

0.007

0.177

5

0.010

0.254

0.012

0.304

6

0.014

0.356

0.016

0.406



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE There are a total of 16 connector links, eight each side, on engine. Installation procedure is same for all. m. Install connector links (4, figure 1) onto actuation ring segments as follows: (1)

Align connector link (4) onto actuation ring segments (5) per position mark on connector link.

(2)

Install two straight pins (1) through connector link (4) into actuation ring segments (5).

(3)

Using four bolts (2), with flat washers (3) under bolthead, secure connector link (4) onto actuation ring segment (5). Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque.

(4)

Repeat steps (1) through (3) for all remaining connector links.

n.

Install two VSV torque shafts onto engine per WP 114 00.

o.

Install all removed piping, wiring, and tubing per WP 113 00 or SWP 113 01.

p.

Install two VSV actuators per WP 100 00. The hydraulic actuation unit, 1C3569, will not be connected directly to each VSV actuator.

q.

Functionally check VSV mechanism as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. CAUTION

(1)

•


•


•


Disconnect VSV actuator rod-end and head-end oil supply hoses at hydraulic pump and connect hydraulic actuator unit, 1C3569, to VSV actuator rod-end and head-end oil supply hoses.





Using hydraulic actuator unit, 1C3569, move VSV actuators from full open to full closed position. Check VSV for binding or rubbing. Correct as required.

(3)

Disconnect hydraulic actuator unit, 1C3569, from VSV actuator rod-end and headend oil supply hoses.

r.

Install rod-end and head-end hoses onto hydraulic pump per WP 120 00.

s.

Motor engine per GEK 105048, Chapter 7.

t.

Check VSV system fluid connectors for leakage.




WORK PACKAGE

TECHNICAL PROCEDURES COMPRESSOR FRONT FRAME REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Compressor Front Frame Installation. .............................................................................. Compressor Front Frame Removal. ...................................................................................

6 4


GEK 105054 Volume II WP 210 00 1.


Introduction. This work package contains instructions for removal and installation of compressor front frame (CFF).

2.

3.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Replacement Gas Generator External Piping and Wiring Removal and Installation Gas Turbine External Piping and Wiring Removal and Installation Gas Generator Inlet Duct Replacement Centerbody Replacement Accessory Gearbox Replacement Radial Drive Shaft Replacement Inlet Gearbox Replacement Gas Generator Miscellaneous Sump Components Replacement Gas Turbine Miscellaneous Sump Components Replacement Gas Generator Miscellaneous Sump Components Inspection Gas Turbine Miscellaneous Sump Components Inspection Compressor Front Frame Inspection

GEK 105054 Chapter 7 GEK 105054 WP 002 00 WP 109 00 WP 113 00 SWP 113 01 WP 204 00 WP 205 00 WP 206 00 WP 207 00 WP 208 00 WP 217 00 SWP 217 01 WP 413 00 SWP 413 01 WP 416 00


Part No.

Fixture, Lift - Gas Generator Turnover Front Frame Shim Set, Blade Tips - Compressor Rotor

1C8332G01 2C6119G02





Marking Pen

Sharpie T.E.C. or Action Marker GE Spec A50TF26 GE Spec A50TF201, or MIL-T-5544

Sealing Compound Thread Lubricant 5.




GEK 105054 Volume II WP 210 00 6.


Compressor Front Frame Removal. a.


b.

Position temporary support under high pressure compressor (HPC) stator casing. CAUTION ENSURE ENGINE WILL BE ADEQUATELY SUPPORTED DURING CFF REMOVAL, OR DAMAGE TO ENGINE WILL OCCUR.

c.

Remove enclosure mounting components on CFF per packager’s manual.

d.

Remove all applicable piping, wiring, and tubing per WP 113 00 or SWP 113 01.

e.

Remove P2/T2 sensor connections per WP 109 00.

f.

Remove inlet duct per WP 204 00.

g.


h.


i.

Remove inlet gearbox per WP 208 00.

j.

Remove accessory gearbox assembly per WP 206 00.

k.

Attach hoist to lift fixture, 1C8332. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY.

l.

Attach lift fixture, 1C8332, onto ground handling mounts of CFF. NOTE Shim set shall support weight of HPC rotor when CFF is removed.

m. Install shim set, 2C6119, between blisk blade tips and inner circumference of lower HPC casing. Install 10 shims in both directions starting at approximately 6:00 o'clock position. n.

Using marking pen, position mark brackets located on CFF/HPC flange (figure 1).




Figure 1. CFF/HPC Flange 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 210 00 o.


Remove 78 bolts and nuts that secure CFF to HPC casings. Remove all brackets attached to flange. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION USE EXTREME CARE WHEN MOVING CFF FORWARD TO AVOID DAMAGING NO. 3 BEARING AND AIR/OIL SEALS.

7.

p.

Using hoist and lift fixture, 1C8332, carefully move CFF forward.

q.

Inspect CFF components per WP 416 00.

r.

Inspect A-sump components per WP 413 00 or SWP 413 01.

Compressor Front Frame Installation. a.

If required, attach hoist to lift fixture, 1C8332.

b.

If required, attach lift fixture, 1C8332, onto ground handling mounts on CFF. CAUTION NO. 3 BEARING INNER AND OUTER RACES ARE MATCHED SET. ENSURE THAT BOTH HAVE SAME SERIAL NUMBER.

c.

If installing new CFF, install No. 3 bearing inner race per WP 217 00 or SWP 217 01. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY.

d.

Using hoist and lift fixture, 1C8332, position CFF in front of HPC stator casings.

e.

Apply thin coating of sealing compound to inner sealing surface of CFF aft flange and HPC forward flange.




CAUTION USE EXTREME CARE WHEN MOVING CFF AFT ONTO HPC ROTOR FORWARD SHAFT, OR DAMAGE TO NO. 3 BEARINGS AND AIR/OIL SEAL MAY OCCUR. f.

Install driftpin in top vertical centerline bolthole to align CFF and HPC flanges and prevent circumferential flange cocking.

g.

Carefully move CFF toward HPC. Maintain alignment with HPC rotor forward shaft to prevent damage to bearings and seals.

h.

If required, position flags from shim set, 2C6119, through CFF so flags shall not become caught between flanges.

i.

Align top of CFF to top of HPC stator casing.

j.

Lightly lubricate 78 bolt threads and self-locking nut contact faces with thread lubricant.

k.

Install 77 bolts, boltheads aft, through CFF/HPC flange. Ensure brackets previously removed are installed in correct locations per position marks.

l.

Install 77 self-locking nuts onto bolts.

m. Remove driftpin located in top vertical centerline hole. n.

Install bolt, bolthead aft, and nut into bolthole at top vertical centerline of CFF.

o.

Tighten all installed bolts to 209-231 lb in. (23.7-26.1 N⋅m) of torque.

p.

Remove shim set, 2C6119, from blisk blade tips and HPC stator casings.

q.

Remove lift fixture, 1C8332, from CFF.

r.

Install inlet gearbox per WP 208 00.

s.

Install accessory gearbox assembly per WP 206 00.

t.

Install radial drive shaft per WP 207 00.

u.

Install centerbody per WP 205 00.

v.

Install inlet duct per WP 204 00.

w.

Install all applicable, piping, tubing, and wiring per WP 113 00 or SWP 113 01.

x.

Install P2/T2 sensor connections per WP 109 00.




y.

Install enclosure mounting components onto CFF per packager’s manual.

z.

Remove temporary support located under HPC stator casing.

aa. Perform engine checkout per GEK 105054, Chapter 7.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR STATOR CASINGS REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 28 ................. 0


Page

Forward High Pressure Stator Top Casing Installation. .................................................. 25 Forward High Pressure Stator Top Casing Removal. ....................................................... 21 High Pressure Stator Casings Installation........................................................................ 16 High Pressure Compressor Stator Casings Removal. ....................................................... 3


GEK 105054 Volume II WP 211 00 1.


Introduction. This work package provides instructions for the removal and installation of the high pressure compressor (HPC) stator casings. An alternate procedure for removing the upper front HPC stator casing is provided as well.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Variable Stator Vane Actuator Replacement Fuel System Replacement Accelerometer Replacement Gas Generator Outside Piping and Wiring Removal and Installation Gas Turbine Outside Piping and Wiring Removal and Installation Variable Stator Vane Torque Shaft Replacement Accessory Gearbox Replacement Radial Drive Shaft Replacement Variable Stator Vane Mechanism Replacement High Pressure Stator Casings Inspection High Pressure Rotor Inspection

GEK 105054 WP 002 00 WP 100 00 WP 101 00 WP 111 00

SWP 113 01 WP 114 00 WP 206 00 WP 207 00 WP 209 00 WP 423 00 WP 424 00


Part No.

Assembly, Hydraulic Actuator Unit Fixture, Raise and Support-Upper Compressor Case Fixture Set, Top Halving-HP Compressor Stator Case Lift Fixture-HPC Stator Casing

1C3569G2/G3 1C8039G02 1C8343G01 1C8350G01



Lubricating Oil

MIL-L-23699 or MIL-L-7808 GE Spec A50TF201 or MIL-T-5544

Thread Lubricant 5.

WP 113 00





High Pressure Compressor Stator Casings Removal. a.


b.

Open variable stator vanes (VSV) to full open position as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Disconnect VSV actuators rod-end and head-end hoses from hydraulic pump. Drain residual lubricating oil into approved waste container. CAUTION

(2)

•


•


•

DO NOT INTERMIX LUBRICATING OILS, MIL-L-7808 AND MIL-L-23699.

Connect hydraulic actuator unit, 1C3569, to VSV actuators rod-end and head-end hoses. WARNING



(4)

Disconnect hydraulic actuator unit, 1C3569, from VSV actuators rod-end and headend hoses.

c.


d.


e.

Remove fuel system components that interfere with HPC stator casing removal per WP 101 00.




f.

Remove all applicable gas generator outside piping and wiring per WP 113 00 or SWP 113 01.

g.

Remove VSV mechanism connector links per WP 209 00. NOTE Removal of radial drive shaft, accessory gearbox, and accelerometer are required only when removing lower HPC stator casing.

h.

Remove accelerometer on HPC aft flange per WP 111 00.

i.


j.

Remove accessory gearbox per WP 206 00.

k.

Remove upper HPC stator casing as follows: (1)

Remove 38 bolts and self-locking nuts from boltholes 1 through 20 and 60 through 78 in HPC stator/compressor front frame (CFF) flange (figure 1). Matchmark and remove brackets from flange as securing hardware is removed.

(2)

Remove 45 bolts and self-locking nuts from boltholes 1 through 23 and 69 through 90 in HPC stator/compressor rear frame (CRF) flange (figure 2 or 3). Matchmark and remove brackets from flange as securing hardware is removed. CAUTION

DO NOT TURN BODY-BOUND BOLTS IN HPC STATOR CASING HORIZONTAL SPLIT-LINE FLANGE, OR DAMAGE TO HPC STATOR CASING SHALL OCCUR. NOTE

•

Body-bound bolts are installed in forward HPC stator casing boltholes 1L, 1R, 5L, 5R, 6L, 6R, 19L, 19R, 22L, 22R, 23L, 23R, 25L, 25R, 31L, 31R, 32L, 32R, 33L, 33R, 34L, 34R, 35L, 35R, 36L, 36R, 37L, 37R, 38L and 38R, and in aft HPC stator casing boltholes 2L, 2R, 8L, and 8R.

•

Body-bound bolts at boltholes19L, 19R, 22L, 22R, 23L, 23R, 25L, and 25R have sleeve spacers installed on them above and below horizontal splitline.

(3)

Remove 47 bolts and self-locking nuts from left HPC stator casing horizontal split-line flange (figure 4).

(4)

Remove 47 bolts and self-locking nuts from right HPC stator casing horizontal split-line flange.




Figure 1. HPC Stator Casing/CFF Flange - All Models 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. HPC Stator Casing/CRF Flange - LM2500+ Model PK 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. HPC Stator Casing/CRF Flange - LM2500+ Models GK, GV, and PV 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 4. HPC Stator Casing Horizontal Split-Line Flanges - All Models 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Attach lift fixture, 1C8350, to upper HPC stator casing (figure 5) as follows: (a) Engage lift fixture, 1C8350, forward pins in boltholes of HPC forward stator casing forward flange. (b) Using adjustment nut, expand lift fixture, 1C8350, so aft pins engage boltholes of HPC aft stator casing aft flange.

(6)

If upper HPC stator casing does not come free of lower HPC stator casing, install upper compressor raise and support fixture, 1C8039, as follows: (a) Remove bolts and self-locking nuts from boltholes 22 and 58 at HPC stator casing/CFF flange (figure 1). (b) Remove bolts and self-locking nuts from boltholes 25 and 67 at HPC stator casing/CRF flange (figure 2 or 3). (c) Install pin (1, figure 6) of jack (4) into bolthole 22 on HPC stator casing/CRF flange. (d) Using bolt (2) and nut (3), attach jack (4) to HPC stator casing/CRF flange at bolthole 25.




Figure 6. Raising Upper HPC Stator Casing Using Raise and Support Fixture, 1C8039

(e) Install pin (1) of jack (4) into bolthole 70 on HPC stator casing/CRF flange. (f) Using bolt (2) and nut (3), attach jack (4) to HPC stator casing/CRF flange at bolthole 67. (g) Install pin (1) of jack (4) into bolthole 19 on HPC stator casing/CFF flange. (h) Using bolt (2) and nut (3), attach jack (4) to HPC stator casing/CFF flange at bolthole 22. (i) Install pin (1) of jack (4) into bolthole 61 on HPC stator casing/CFF flange. (j)

Using bolt (2) and nut (3), attach jack (4) to HPC stator casing/CFF flange at bolthole 58.

(k) Using handle (6), rotate knurled knob (5) of jack (4) 1/4 turn at each location to raise upper HPC stator casing.




(l) Repeat step (6) until upper HPC stator casing is broken free of lower HPC stator casing. (m) Remove upper compressor raise and support fixture, 1C8039, from HPC stator casing at four locations. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY.

l.

(7)

Using hoist and lift fixture, 1C8350, raise upper HPC stator casing away from engine.

(8)

Place upper HPC stator casing on work surface for further disassembly or move to safe area for storage.

(9)

Inspect upper HPC stator casing per WP 423 00.

If desired, separate upper forward HPC stator casing from upper aft HPC stator casing as follows: (1)

Using marking pen, matchmark any brackets located on HPC forward stator casing/HPC aft stator casing flange.

(2)

Remove 46 bolts and self-locking nuts from HPC forward stator casing/HPC aft stator casing flange.

m. Inspect HPC rotor per WP 424 00. n.

Remove lower HPC stator casing as follows: CAUTION UPPER AND LOWER HPC STATOR CASINGS ARE MATCHED SETS. IF REPLACEMENT OF EITHER UPPER OR LOWER SECTION IS REQUIRED, BOTH CASINGS SHALL REQUIRE REPLACEMENT. (1)

If separated, join upper forward HPC stator casing to upper aft HPC stator casing as follows: (a) Lightly coat threads and contact faces of 46 bolts and contact faces of 46 self-locking nuts with thread lubricant. (b) Install 46 bolts, boltheads forward, through upper forward HPC stator casing aft flange (figure 7 or 8). Install brackets onto aft flange per matchmarked locations.




Figure 7. Forward HPC Stator Casing/Aft HPC Stator Casing Flange - LM2500+ Model PK 12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 8. Forward HPC Stator Casing/Aft HPC Stator Casing Flange - LM2500+ Models GK, GV, and PV 13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (c) Align upper aft HPC stator casing with upper forward HPC stator casing. Install brackets onto forward flange of upper aft HPC stator casing per matchmarked locations. (d) Using 46 bolts and self-locking nuts, attach upper forward HPC stator casing onto upper aft HPC stator casing. (e) Tighten 46 bolts to 380-420 lb in. (43.0-47.4 N⋅m) of torque. NOTE

•

Clamping soft material over lower HPC stator casing horizontal split-line flange will ensure retention of fixed HPC stator vanes during removal of lower HPC stator casing.

•

Soft material is considered cardboard, wood, aluminum, or any material softer than HPC stator casing.

(2)

Clamp soft material over lower HPC stator casing left and right horizontal split-line flange. CAUTION

ENSURE LOCKING KEYS ARE PROPERLY INSTALLED ON UPPER HPC STATOR CASING HORIZONTAL SPLIT-LINE FLANGE OR FIXED HPC STATOR BLADES WILL FALL OUT OF UPPER HPC STATOR CASING DURING ASSEMBLY. (3)

Install lift fixture, 1C8350, onto upper HPC stator casing as follows: (a) Engage lift fixture, 1C8350, forward pins in boltholes of HPC forward stator casing forward flange. (b) Using adjustment nut, expand lift fixture, 1C8350, so aft pins engage boltholes of HPC aft stator casing aft flange. WARNING


Using hoist and lift fixture, 1C8350, raise upper HPC stator casing and align on lower HPC stator casing horizontal split-line flange.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION DO NOT TURN BODY-BOUND BOLTS, OR DAMAGE TO HPC STATOR CASING SHALL OCCUR. NOTE

•

Body-bound bolts are installed in forward HPC stator casing boltholes 1L, 1R, 5L, 5R, 6L, 6R, 19L, 19R, 22L, 22R, 23L, 23R, 25L, 25R, 31L, 31R, 32L, 32R, 33L, 33R, 34L, 34R, 35L, 35R, 36L, 36R, 37L, 37R, 38L and 38R, and in aft HPC stator casing boltholes 2L, 2R, 8L, and 8R.

•

Body-bound bolts at boltholes 19L, 19R, 22L, 22R, 23L, 23R, 25L and 25R have sleeve spacers installed on them above and below horizontal splitline.

(5)

Install 47 bolts into left, ALF, horizontal split-line flange per paragraph 7. Tighten nuts hand-tight.

(6)

Install 47 bolts into right, ALF, horizontal split-line flange per paragraph 7. Tighten nuts hand-tight.

(7)

Remove lift fixture, 1C8350, from upper HPC stator casing.

(8)

Remove remaining bolts and self-locking nuts from boltholes in HPC stator/CFF flange (figure 1). Matchmark and remove brackets from flange as securing hardware is removed.

(9)

Remove remaining bolts and self-locking nuts from boltholes in HPC stator/CRF flange (figure 2 or 3). Matchmark and remove brackets from flange as securing hardware is removed.

(10) Carefully rotate lower HPC stator casing radially around engine 180 degrees so upper HPC stator casing is in lower HPC stator casing position. (11) Install bolts and self-locking nuts temporarily into boltholes 21 through 59 in HPC stator/CFF flange (figure 1). Tighten bolts hand-tight. (12) Install bolts and self-locking nuts temporarily into boltholes 24 through 68 in HPC stator/CRF flange (figure 2 or 3). Tighten bolts hand-tight. (13) Attach lift fixture, 1C8350, to lower HPC stator casing as follows: (a) Engage lift fixture, 1C8350, forward pins in boltholes of HPC forward stator casing forward flange. (b) Using adjustment nut, expand lift fixture, 1C8350, so aft pins engage boltholes of HPC aft stator casing aft flange.




USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (14) Using hoist and lift fixture, 1C8350, raise lower HPC stator casing away from engine. (15) Place lower HPC stator casing on work surface for further disassembly or move to safe area for storage. (16) Inspect HPC stator casing per WP 423 00. o.

7.

If desired, separate lower forward HPC stator casing from lower aft HPC stator casing as follows: (1)

Using marking pen, matchmark any brackets located on lower HPC forward stator casing/HPC aft stator casing flange.

(2)

Remove 46 bolts and self-locking nuts from lower HPC forward stator casing/HPC aft stator casing flange.

High Pressure Stator Casings Installation. a.

If disassembled, join lower forward HPC stator casing to lower aft HPC stator casing (figure 7 or 8) as follows: CAUTION UPPER AND LOWER HPC STATOR CASINGS ARE MATCHED SETS. IF REPLACEMENT OF EITHER UPPER OR LOWER SECTION IS REQUIRED, BOTH CASINGS SHALL REQUIRE REPLACEMENT. (1)

Lightly coat threads and contact faces of 46 bolts and contact faces of 46 self-locking nuts with thread lubricant.

(2)

Install 46 bolts, boltheads forward, through lower forward HPC stator casing aft flange. Install brackets onto aft flange per matchmarked locations.

(3)

Align lower aft HPC stator casing with lower forward HPC stator casing. Install brackets onto forward flange of lower aft HPC stator casing per matchmarked locations.

(4)

Using 46 bolts and self-locking nuts, attach lower forward HPC stator casing onto lower aft HPC stator casing.

(5)

Tighten 46 bolts to 380-420 lb in. (43.0-47.4 N⋅m) of torque.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines b.

Install lower HPC stator casing onto engine as follows: NOTE

•

Clamping soft material over lower HPC stator casing flange will ensure retention of fixed HPC stator vanes during removal of lower HPC stator casing.

•

Soft material is considered cardboard, wood, aluminum, or any material softer than HPC stator casing.

(1)

Clamp soft material over lower HPC stator casing left and right horizontal split-line flanges.

(2)

Install lift fixture, 1C8350, onto lower HPC stator casing as follows: (a) Engage lift fixture, 1C8350, forward pins in boltholes of HPC forward stator casing forward flange. (b) Using adjustment nut, expand lift fixture, 1C8350, so aft pins engage boltholes of HPC aft stator casing aft flange. WARNING


Using hoist and lift fixture, 1C8350, raise lower HPC stator casing and align on upper HPC stator casing horizontal split-line flange.

(4)

Remove soft material from lower HPC stator casing horizontal split-line flanges.

(5)

Install horizontal split-line flange bolts in aft HPC stator casing (figure 4) as follows: NOTE

•

Horizontal split-line flange bolthole numbering starts at aft end of HPC stator casing and indexes forward.

•

L refers to 9:00 o’clock position flange, ALF, and R refers to 3:00 o’clock position flange. (a) Using thread lubricant, lightly coat bolt threads and contact faces of 18 bolts and self-locking nuts.




DO NOT TURN BODY-BOUND BOLTS, OR DAMAGE TO HPC STATOR CASING SHALL OCCUR. (b) Install bolts, boltheads up, and self-locking nuts in horizontal split-line of aft HPC stator casing. Ensure body-bound bolts are installed in boltholes 2L, 2R, 8L, and 8R. (c) Tighten self-locking nuts hand-tight, starting at aft end and working forward, alternating sides (1L, 1R, 2L, 2R...9L, and 9R). Tighten bolts hand-tight. (6)

Install horizontal flange bolts in forward HPC stator casing as follows: NOTE

•

Horizontal flange bolthole numbering starts at aft end of HPC stator casing and indexes forward.

•

L refers to 9:00 o’clock position flange, aft looking forward, and R refers to 3:00 o’clock position flange. (a) Using thread lubricant, lightly coat bolt threads and contact faces of 76 bolts and self-locking nuts. CAUTION

DO NOT TURN BODY-BOUND BOLTS, OR DAMAGE TO HPC STATOR CASING SHALL OCCUR. (b) Install bolts, boltheads up, in horizontal split-line of forward HPC stator casing. Ensure body-bound bolts are installed in boltholes 1L, 1R, 5L, 5R, 6L, 6R, 19L, 19R, 22L, 22R, 23L, 23R, 25L, 25R, 31L, 31R, 32L, 32R, 33L, 33R, 34L, 34R, 35L, 35R, 36L, 36R, 37L, 37R, 38L, and 38R. (c) Install self-locking nuts onto bolts. Install spacers onto bolts, under self-locking nuts, at boltholes 19L, 19R, 22L, 22R, 23L, 23R, 25L, and 25R. (d) Tighten self-locking nuts hand-tight, starting at aft end and working forward, alternating sides (1L, 1R, 2L, 2R...38L, and 38R). Tighten bolts hand-tight. (7)

Remove lift fixture, 1C8350, from lower HPC stator casing.

(8)

Remove bolts and self-locking nuts temporarily installed into boltholes 21 through 59 in HPC stator/CFF flange (figure 1).




Remove bolts and self-locking nuts temporarily installed into boltholes 24 through 68 in HPC stator/CRF flange (figure 2 or 3).

(10) Carefully rotate lower HPC stator casing radially around engine 180 degrees so upper HPC stator casing is correctly orientated. (11) Using thread lubricant, lightly coat bolt threads and contact faces of 78 bolts and self-locking nuts. (12) Install 78 bolts and self-locking nuts in HPC stator/CFF flange (figure 1). Install bolts with boltheads facing aft. Install brackets per matchmarked locations. Tighten bolts to 209-231 lb in. (23.7-26.1 N⋅m) of torque. (13) Using thread lubricant, lightly coat bolt threads and contact faces of 90 bolts and self-locking nuts. (14) Install 90 bolts and self-locking nuts in HPC stator/CRF flange (figure 2 or 3). Install bolts with boltheads facing forward. Install brackets per matchmarked locations. Tighten bolts to 209-231 lb in. (23.7-26.1 N⋅m) of torque. (15) Final tighten horizontal split-line flange bolts to final torque per tables 1 and 2. c.

If removed, install accessory gearbox per WP 206 00.

d.

If removed, install radial drive shaft per WP 207 00. Table 1. Horizontal Split-Line Bolt Installation-Aft HPC Stator Casing

BodyBound Bolt

X

X

Hole

Bolt (Inches)

Self-Locking Nut (Inches)

1 2 3 4 5 6 7 8 9

0.375-24 x 1.438 0.375-24 x 1.41 0.375-24 x 1.438 0.375-24 x 1.438 0.375-24 x 1.375 0.375-24 x 1.375 0.375-24 x 1.375 0.375-24 x 1.26 0.375-24 x 1.375

0.375-24 0.375-24 0.375-24 0.375-24 0.375-24 0.375-24 0.375-24 0.375-24 0.375-24

Torque Lb in. 380-420 380-420 380-420 380-420 380-420 380-420 380-420 380-420 380-420

N⋅m 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4




Table 2. Horizontal Split-Line Bolt Installation-Forward HPC Stator Casing BodyBound Bolt X

X X

X

X X X

X X X X X X X X

Hole

Bolt (Inches)

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

0.4375-20 x 1.75 0.375-24 x 1.625 0.375-24 x 1.625 0.375-24 x 1.625 0.4375-20 x 1.75 0.4375-20 x 1.75 0.375-24 x 1.438 0.375-24 x 1.438 0.375-24 x 1.438 0.375-24 x 1.438 0.375-24 x 1.438 0.375-24 x 1.438 0.375-24 x 1.125 0.3125-24 x 0.812 0.3125-24 x 0.812 0.3125-24 x 0.812 0.3125-24 x 0.812 0.3125-24 x 0.812 0.3125-24 x 1.38 0.3125-24 x 0.812 0.3125-24 x 0.812 0.3125-24 x 1.38 0.3125-24 x 1.38 0.3125-24 x 0.812 0.3125-24 x 1.38 0.3125-24 x 0.812 0.3125-24 x 0.812 0.3125-24 x 0.812 0.3125-24 x 0.812 0.3125-24 x 0.812 0.500-20 x 1.602 0.500-20 x 1.602 0.500-20 x 1.602 0.500-20 x 1.602 0.500-20 x 1.602 0.500-20 x 1.602 0.500-20 x 1.30 0.500-20 x 1.602

Spacer

X

X X X

Torque

Self-Locking Nut (Inches)

Lb in.

0.4375-20 0.375-24 0.375-24 0.375-24 0.4375-20 0.4375-20 0.375-24 0.375-24 0.375-24 0.375-24 0.375-24 0.375-24 0.375-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.3125-24 0.500-20 0.500-20 0.500-20 0.500-20 0.500-20 0.500-20 0.500-20 0.500-20

570-630 380-420 380-420 380-420 570-630 570-630 380-420 380-420 380-420 380-420 380-420 380-420 380-420 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 209-231 855-945 855-945 855-945 855-945 855-945 855-945 855-945 855-945

N⋅m 64.5-71.1 43.0-47.4 43.0-47.4 43.0-47.4 64.5-71.1 64.5-71.1 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4 43.0-47.4 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 23.7-26.1 96.7-106.7 96.7-106.7 96.7-106.7 96.7-106.7 96.7-106.7 96.7-106.7 96.7-106.7 96.7-106.7




8.

e.

If removed, install accelerometer on HPC aft flange per WP 111 00.

f.

Install VSV mechanism connector links per WP 209 00.

g.

Install two VSV actuators from engine per WP 100 00.

h.

Install two VSV torque shafts from engine per WP 114 00.

i.

Install all applicable gas generator outside piping and wiring per WP 113 00 or SWP 113 01.

j.

Install fuel system components that interfere with HPC stator casing removal per WP 101 00.

Forward High Pressure Stator Top Casing Removal. a.


b.

Open variable stator vanes (VSV) to full open position as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Disconnect VSV actuators rod-end and head-end hoses at hydraulic pump. Drain residual lubricating oil into approved waste container. CAUTION

(2)

•


•


•

DO NOT INTERMIX LUBRICATING OILS, MIL-L-7808 AND MIL-L-23699.

Connect hydraulic actuator unit, 1C3569, to VSV actuators rod-end and head-end hoses.






(4)

Disconnect hydraulic actuator unit, 1C3569, from VSV actuators rod-end and head-end hoses.

c.


d.


e.

Remove fuel system components that interfere with HPC stator casing removal per WP 101 00.

f.

Remove all applicable gas generator outside piping and wiring per WP 113 00 or SWP 113 01.

g.

Remove VSV mechanism connector links per WP 209 00.

h.

Release upper HPC stator casing from lower HPC stator casing as follows: (1)

Remove 38 bolts and self-locking nuts from boltholes 1 through 20 and 60 through 78 in HPC stator/compressor front frame (CFF) flange (figure 1). Matchmark and remove brackets from flange as securing hardware is removed.

(2)

Remove 46 bolts and self-locking nuts from boltholes 1 through 23 and 70 through 92 in forward HPC stator/aft HPC stator casing flange (figure 7 or 8). Matchmark and remove brackets from flange as securing hardware is removed. CAUTION

DO NOT TURN BODY-BOUND BOLTS, OR DAMAGE TO HPC STATOR CASING SHALL OCCUR. NOTE

•

Body-bound bolts are installed in forward HPC stator casing boltholes 1L, 1R, 5L, 5R, 6L, 6R, 19L, 19R, 22L, 22R, 23L, 23R, 25L, 25R, 31L, 31R, 32L, 32R, 33L, 33R, 34L, 34R, 35L, 35R, 36L, 36R, 37L, 37R, 38L, and 38R.

•

Body-bound bolts at boltholes 19L, 19R, 22L, 22R, 23L, 23R, 25L and 25R have sleeve spacers installed on them above and below horizontal splitline.

(3)

Remove 38 bolts and self-locking nuts from left forward HPC stator casing horizontal split-line flange (figure 4).




(4)

Remove 38 bolts and self-locking nuts from right forward HPC stator casing horizontal split-line flange.

(5)

Install upper compressor case raise and support fixture, 1C8039, as follows: (a) Remove bolts and self-locking nuts from boltholes 22 and 58 at HPC stator casing/CFF flange (figure 1). (b) Remove bolts and self-locking nuts from boltholes 25 and 67 at forward HPC stator casing/aft HPC stator casing flange (figure 7 or 8). (c) Install pin (1, figure 9) of jack (4) into bolthole 22 on forward HPC stator casing/aft HPC stator casing flange. (d) Using bolt (2) and nut (3), jack (4) to forward HPC stator casing/aft HPC stator casing flange at bolthole 25. (e) Install pin (1) of jack (4) into bolthole 71 on forward HPC stator casing/aft HPC stator casing flange. (f) Using bolt (2) and nut (3), attach jack (4) to forward HPC stator casing/aft HPC stator casing flange at bolthole 68. (g) Install pin (1) of upper compressor case raise and support fixture, 1C8039, into bolthole 19 on HPC stator casing/CFF flange. (h) Using bolt (2) and nut (3), attach jack (4) to HPC stator casing/CFF flange at bolthole 22. (i) Install pin (1) of jack (4) into bolthole 61 on HPC stator casing/CFF flange. (j)

Using bolt (2) and nut (3), attach jack (4) to HPC stator casing/CFF flange at bolthole 58.

(k) Using handle (6), rotate knurled knob (5) of jack (4) 1/4 turn at each location to raise upper HPC stator casing. (l) Repeat step (k) until upper HPC stator casing is separated from the lower stator casing by at least 1.0625 inches (26.988 mm).




Figure 9. Raising Upper Forward HPC Stator Casing Using Raise and Support Fixture, 1C8039 CAUTION UPPER AND LOWER HPC STATOR CASINGS ARE MATCHED SETS. IF REPLACEMENT OF EITHER UPPER OR LOWER SECTION IS REQUIRED, BOTH CASINGS SHALL REQUIRE REPLACEMENT. i.

Install HPC top halving fixture set, 1C8343, as follows: NOTE Horizontal flange bolthole numbering starts at aft end of HPC stator casing and indexes forward. (1)

Using eight bolts (3, figure 10) install aft hinge fixture (4) onto left, ALF, HPC stator casing horizontal split-line flange in boltholes 1, 3, 4, and 5.

(2)

Using 10 bolts (5) install forward hinge fixture (6) onto left, ALF, HPC stator casing horizontal split-line flange in boltholes 31 through 35.




j.

Using five bolts (5) and four bolts (3), install lift handle (7) onto upper HPC stator casing right, ALF, horizontal split-line flange. Use same bolthole numbers as used for installing hinges (4 and 6).

Disengage and remove all raise and support fixture, 1C8039, components. CAUTION

k.

l. 9.

•

USE EXTREME CARE WHEN HPC STATOR CASINGS ARE OPEN, NOT TO DROP ANY OBJECT INTO LOWER HPC STATOR CASING.

•

DO NOT LAY TOOLS OR PARTS ON HORIZONTAL SPLIT-LINE FLANGES.

•

REMOVE ALL OBJECTS FROM SHIRT POCKETS PRIOR TO LEANING OVER HPC ROTOR OR LOWER HPC STATOR CASING.

•

SHOULD ANY OBJECT BE ACCIDENTALLY DROPPED INTO LOWER HPC STATOR CASING, IMMEDIATELY STOP ALL OPERATIONS AND RETRIEVE OBJECT.

•

DO NOT LEAVE ENGINE UNATTENDED WHILE UPPER HPC STATOR CASING IS OPEN, UNLESS HPC ROTOR AND LOWER HPC STATOR CASING ARE PROPERLY COVERED.

Open upper forward HPC stator casing as follows: (1)

Using lift handle (7), raise upper stator case to approximately 45 degrees.

(2)

Attach upper end of stanchion (1) to upper HPC stator casing forward flange using quick-release pin (2).

(3)

Attach lower end of stanchion (1) CFF aft flange using quick-release pin (2).

Inspect HPC rotor per WP 424 00.

Forward High Pressure Stator Top Casing Installation. a.

Close upper forward HPC stator casing as follows: (1)

Support upper stator case and remove quick-release pin (2, figure 10) from stanchion (1) and CFF flange bolthole.

(2)

Remove quick-release pin (2) from stanchion (1) and forward HPC stator casing flange bolthole. Remove stanchion and lower HPC stator casing.

(3)

Install upper compressor case raise and support fixture, 1C8039, per paragraph 8, step h. (5).




Figure 10. HPC Top Halving Fixture Set, 1C8343 26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



b.

(4)

Remove five bolts (5) and four bolts (3) that secure lift handle (7) to upper forward HPC stator casing horizontal split-line flange.

(5)

Remove lift handle (7) from upper HPC stator casing horizontal split-line flange.

(6)

Remove 10 bolts (5) that secure forward hinge (6) to forward HPC stator casing horizontal split-line flange.

(7)

Remove eight bolts (3) that secure aft hinge (4) to forward HPC stator casing horizontal split-line flange.

(8)

Using handle (6, figure 9), rotate knurled knob of jack (4) 1/4 turn at each location to lower forward HPC stator casing.

Install horizontal flange bolts in forward HPC stator casing per table 2 and as follows: NOTE

•

Horizontal flange bolthole numbering starts at aft end of HPC stator casing and indexes forward.

•

L refers to 9:00 o’clock position flange, aft looking forward, and R refers to 3:00 o’clock position flange.

(1)

Using thread lubricant, lightly coat bolt threads and contact faces of 72 bolts and self-locking nuts. CAUTION

DO NOT TURN BODY-BOUND BOLTS, OR DAMAGE TO HPC STATOR CASING SHALL OCCUR. (2)

Install bolts, boltheads up, and self-locking nuts in horizontal split-line of forward HPC stator casing. Ensure body-bound bolts are installed in boltholes 1L, 1R, 5L, 5R, 6L, 6R, 19L, 19R, 22L, 22R, 23L, 23R, 25L, 25R, 31L, 31R, 32L, 32R, 33L, 33R, 34L, 34R, 35L, 35R, 36L, 36R, 37L, 37R, 38L, and 38R. NOTE

Sleeve spacers are installed on both sides of horizontal split-line. (3)

Install sleeve spacers onto bolts, under self-locking nuts, at boltholes 19L, 19R, 22L, 22R, 23L, 23R, 25L, and 25R.

(4)

Tighten self-locking nuts hand-tight, starting at aft end and working forward, alternating sides (1L, 1R, 2L, 2R, 38L, and 38R). Tighten bolts hand-tight.




(5)


(6)

Install 38 bolts and self-locking nuts into boltholes 1 through 20 and 60 through 78 in HPC stator/CFF flange (figure 1). Install brackets per matchmarks on flange as securing hardware is installed. Tighten bolt hand-tight.

(7)


(8)

Install 46 bolts and self-locking nuts into boltholes 1 through 23 and 70 through 92 in forward HPC stator/aft HPC stator casing flange (figures 7 or 8). Install brackets per matchmarks on flange as securing hardware is installed. Tighten bolt hand-tight.

(9)

Final-tighten all circumferential flange bolts to 209-231 lb in. (23.7-26.1 N⋅m) of torque.

(10) Final tighten horizontal split-line flange bolts to final torque per table 2. c.

Install VSV mechanism connector links per WP 209 00.

d.

Install two VSV actuators onto engine per WP 100 00.

e.

Install two VSV torque shafts onto engine per WP 114 00.

f.

Install all applicable gas generator outside piping and wiring per WP 113 00 or SWP 113 01.

g.

Install fuel system components per WP 101 00.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR VARIABLE STATOR VANE REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Variable Stator Vane Installation. ..................................................................................... Variable Stator Vane Removal. ..........................................................................................

9 3


GEK 105054 Volume II WP 212 00 1.


Introduction. This work package provides instructions for the removal and installation of the variable stator vanes (VSV).

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Variable Stator Vane Mechanism Replacement High Pressure Compressor Stator Casings Replacement High Pressure Compressor Variable Stator Vane Shroud Replacement Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 209 00 WP 211 00 WP 213 00 GEK 105055


Part No.


1C8324G01



Marking Pen

Sharpie T.E.C. or Action Marker


IPB Figure No./Item

Spacer, IGV Spacer, Stage 0 Spacer, Stages 1-2 Spacer, Stages 3-4 Spacer, Stages 5-6

12-5 12-17 12-29 12-47 12-55




Variable Stator Vane Removal. a.


b.

Remove VSV mechanism per WP 209 00. CAUTION ENSURE VSV IS TEMPORARILY SECURED DURING REMOVAL, OR DAMAGE DUE TO DROPPING MAY OCCUR. NOTE There are four inlet guide vanes (IGV) at high pressure compressor (HPC) stator casing split-line. Removal procedure is same for all.

c.

Remove HPC stator casing per WP 211 00.

d.

Remove IGVs (1, figure 1) at HPC stator casing split-line as follows: (1)

If same IGV and components are to be reinstalled, position mark IGV components using marking pen.

(2)

Install VSV holder, 1C8324P02, onto IGVs.

(3)

Remove self-locking nut (3) that secures IGV (1) to HPC stator casing (6).

(4)

Remove stage IGV actuation arm (11) from IGV (1).

(5)

Remove shroud at ID of IGV per WP 213 00.

(6)

Pull IGV (1) from HPC stator casing (6). NOTE

There are 38 stage IGVs at positions other than the HPC stator casing split-line. Removal procedure is same for all. e.

Remove all other IGVs (1) as follows: (1)

If same IGV and components are to be reinstalled, position mark IGV components using marking pen.

(2)

Install VSV holder, 1C8324P02, onto IGVs.

(3)

Remove self-locking nut (3) that secures IGV (1) to HPC stator casing (6).

(4)

Remove sleeve (10) from IGV (1).




Figure 1. VSV Components (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. VSV Components (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



(5)

Remove stage IGV lever arm (4) from stage IGV vane (1).

(6)

Remove shroud at ID of IGV per WP 213 00.

(7)

Pull IGV (1) from HPC stator casing (6). NOTE

There are 40 stage 0 vanes. Removal procedure is same for all. f.

Remove stage 0 vanes (2) as follows: (1)

If same stage 0 vane and components are to be reinstalled, position mark stage 0 vane components using marking pen.

(2)

Install VSV holder, 1C8324P03, onto stage 0 vanes.

(3)

Remove self-locking nut (3) that secures stage 0 vane (2) to HPC stator casing (6).

(4)

Remove sleeve (10) from stage 0 vane (2).

(5)

Remove stage 0 actuation arm (5) from stage 0 vane (2).

(6)

Remove shroud at ID of stage 0 VSVs per WP 213 00.

(7)

Pull stage 0 vane (2) from HPC stator casing (6). NOTE

There are 36 stage 1 vanes. Removal procedure is same for all. g.



(2)


(3)


(4)


(5)


(6)






There are 40 stage 2 vanes. Removal procedure is same for all. h.



(2)


(3)


(4)


(5)


(6)


(7)


There are 46 stage 3 vanes. Removal procedure is same for all. i.



(2)


(3)


(4)


(5)


(6)

Pull stage 3 vane (16) from HPC stator casing (6).




There are 50 stage 4 vanes. Removal procedure is same for all. j.



(2)


(3)


(4)


(5)


(6)


There are 58 stage 5 vanes. Removal procedure is same for all. k.



(2)


(3)


(4)


(5)


(6)


There are 64 stage 6 vanes. Removal procedure is same for all. l.



(2)


(3)






(5)


(6)

Pull stage 6 vane (21) from HPC stator casing (6).

m. If applicable, remove spacer(s) (9) from HPC stator casing (6). n.

If applicable, remove glass backed bushing(s) (8) from HPC stator casing (6). NOTE Flanged washer may be retained with VSV during removal.

o. 7.

If applicable, remove flanged washer(s) (7) from HPC stator casing (6) or VSV.

Variable Stator Vane Installation. NOTE

a.

•

There are 64 stage 6 vanes. Installation procedure is same for all.

•

Length of replacement vanes shall not exceed length of adjacent vanes.

•

If an entire stage of replacement vanes is required, contact GE Customer Service to obtain a preground set.

Install stage 6 vanes (21) as follows: (1)

If flanged washer (7) was removed from HPC stator casing (6), install flanged washer onto stage 6 vane (21).

(2)

If glass backed bushing (8) was removed from HPC stator casing (6), install glass backed bushing onto HPC stator casing.

(3)

If spacer (9) was removed from HPC stator casing (6), install spacer onto HPC stator casing, chamfer side facing radially outward.

(4)

Install stage 6 vane (21) through HPC stator casing (6).

(5)

Install sleeve (10) onto stage 6 vane (21).

(6)

Install stage 6 actuation arm (23) onto stage 6 vane (21).

(7)

Install self-locking nut (3) onto stage 6 vane (21) as follows: (a) Install VSV holder, 1C8324P09, onto stage 6 vanes (21). (b) Tighten self-locking nut (3) to 85-95 lb in. (9.6-10.7 N⋅m) of torque. 9




Figure 2. VSV Angle Measurement

Table 1. Vane Angles Stage

Open

Closed

IGV

45°00′

45°00′

0

30°00′

30°00′

1

30°15′

30°15′

2

26°45′

26°45′

3

25°00′

25°00′

4

23°45′

23°45′

5

30°00′

30°00′

6

30°00′

30°00′




Rotate stage 6 vane (21) through mechanical travel limits of table 1 and figure 2. Stage 6 vane will exhibit no interference or binding during rotation.

(9)

Measure rotational torque for each stage 6 vane. Rotational torque shall be 1.0-10.0 lb in. (0.1-1.1 N⋅m). If rotational torque requirement is exceeded, proceed as follows: (a) Disassemble stage 6 vane (21). (b) Consult Illustrated Parts Breakdown, GEK 105055, for selection of spacer (9) replacement. (c) Using different spacer (9), reassemble stage 6 vane (21) per steps (4) through (8). (d) Repeat steps (8) and (9). NOTE

b.

•


•


•




(2)


(3)


(4)


(5)


(6)


(7)

Install self-locking nut (3) onto stage 5 vane (20) as follows: (a) Install VSV holder, 1C8324P08, onto stage 5 vane (20). (b) Tighten self-locking nut (3) to 85-95 lb in. (9.6-10.7 N⋅m) of torque. 11




(8)


(9)


c.

•


•


•




(2)


(3)


(4)


(5)


(6)


(7)

Install self-locking nut (3) onto stage 4 vane (17) as follows: (a) Install VSV holder, 1C8324P07, onto stage 4 vane (17). (b) Tighten self-locking nut (3) to 85-95 lb in. (9.6-10.7 N⋅m) of torque.





(9)


d.

•


•


•




(2)


(3)


(4)


(5)


(6)


(7)

Install self-locking nut (3) onto stage 3 vane (16) as follows: (a) Install VSV holder, 1C8324P06, onto stage 3 vane (16). (b) Tighten self-locking nut (3) to 85-95 lb in. (9.6-10.7 N⋅m) of torque. 13




(8)


(9)


There are 40 stage 2 vanes. Installation procedure is same for all. e.



(2)


(3)


(4)


(5)


(6)


(7)


(8)

Install shroud on ID of stage 2 VSVs per WP 213 00.

(9)





(10) Measure rotational torque for each stage 2 vane. Rotational torque shall be 1.0-10.0 lb in. (0.1-1.1 N⋅m). If rotational torque requirement is exceeded, proceed as follows: (a) Disassemble stage 2 vane (13). (b) Consult Illustrated Parts Breakdown, GEK 105055, for selection of spacer (9) replacement. (c) Using different spacer (9), reassemble stage 2 vane (13) per steps (4) through (8). (d) Repeat steps (9) and (10). NOTE There are 36 stage 1 vanes. Installation procedure is same for all. f.



(2)


(3)


(4)


(5)


(6)


(7)


(8)


(9)





(10) Measure rotational torque for each stage 1 vane. Rotational torque shall be 1.0-10.0 lb in. (0.1-1.1 N⋅m). If rotational torque requirement is exceeded, proceed as follows: (a) Disassemble stage 1 vane (12). (b) Consult Illustrated Parts Breakdown, GEK 105055, for selection of spacer (9) replacement. (c) Using different spacer (9), reassemble stage 1 vane (12) per steps (4) through (8). (d) Repeat steps (9) and (10). NOTE There are 40 stage 0 vanes. Installation procedure is same for all. g.



(2)


(3)


(4)


(5)


(6)


(7)


(8)


(9)





(10) Measure rotational torque for each stage 0 vane. Rotational torque shall be 1.0-10.0 lb in. (0.1-1.1 N⋅m). If rotational torque requirement is exceeded, proceed as follows: (a) Disassemble stage 0 vane (2). (b) Consult Illustrated Parts Breakdown, GEK 105055, for selection of spacer (9) replacement. (c) Using different spacer (9), reassemble stage 0 vane (2) per steps (4) through (8). (d) Repeat steps (9) and (10). NOTE There are four IGVs at HPC stator casing split-line. Installation procedure is same for all. h.

Install four IGVs (1) at HPC stator casing split-line as follows: (1)

If flanged washer (7) was removed from HPC stator casing (6), install flanged washer onto stage IGV vane (1).

(2)


(3)


(4)

Install IGV (1) through HPC stator casing (6).

(5)

Install IGV actuation arm (11) onto IGV (1).

(6)

Install self-locking nut (3) onto IGV (1) as follows: (a) Install VSV holder, 1C8324P02, onto IGV vane (1). (b) Tighten self-locking nut (3) to 85-95 lb in. (9.6-10.7 N⋅m) of torque.

(7)

Install shroud to ID of IGVs per WP 213 00.

(8)

Rotate IGV (1) through mechanical travel limits of table 1 and figure 2. IGV will exhibit no interference or binding during rotation.


GEK 105054 Volume II WP 212 00 (9)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Measure rotational torque for four IGVs (1). Rotational torque shall be 1.0-10.0 lb in. (0.1-1.1 N⋅m). If rotational torque requirement is exceeded, proceed as follows: (a) Disassemble IGV (1). (b) Consult Illustrated Parts Breakdown, GEK 105055, for selection of spacer (9) replacement. (c) Using different spacer (9), reassemble IGV (1) per steps (4) through (8). (d) Repeat steps (8) and (9). NOTE

There are 38 IGVs at positions other than the HPC stator casing split-line. Installation procedure is same for all. i.

Install all other IGVs (1) as follows: (1)

If flanged washer (7) was removed from HPC stator casing (6), install flanged washer onto stage IGV vane (1).

(2)


(3)


(4)

Install IGV (1) through HPC stator casing (6).

(5)

Install IGV actuation arm (4) onto IGV (1).

(6)

Install sleeve (10) onto IGV (1).

(7)

Install self-locking nut (3) onto IGV (1) as follows: (a) Install VSV holder, 1C8324P02, onto IGVs (1). (b) Tighten self-locking nut (3) to 85-95 lb in. (9.6-10.7 N⋅m) of torque.

(8)

Install shroud on ID of IGVs per WP 213 00.

(9)

Rotate IGV (1) through mechanical travel limits of table 1 and figure 2. IGV will exhibit no interference or binding during rotation.




(10) Measure rotational torque for remaining IGVs (1). Rotational torque shall be 1.0-10.0 lb in. (0.1-1.1 N⋅m). If rotational torque requirement is exceeded, proceed as follows: (a) Disassemble IGV (1). (b) Consult Illustrated Parts Breakdown, GEK 105055, for selection of spacer (9) replacement. (c) Using different spacer (9), reassemble IGV (1) per steps (4) through (8). (d) Repeat steps (9) and (10). j.

Install VSV mechanism per WP 209 00.

k.

Install HPC stator casings per WP 211 00.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR VARIABLE STATOR VANE SHROUD REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Variable Stator Vane Shroud Installation. ........................................................................ Variable Stator Vane Shroud Removal. .............................................................................

7 3


GEK 105054 Volume II WP 213 00 1.


Introduction. This work package provides instructions for the removal and installation of the variable stator vane (VSV) shrouds.

2.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices High Pressure Compressor Stator Casings Replacement High Pressure Compressor Variable Stator Vane Shrouds Inspection

GEK 105054 Chapter 7 GEK 105054 WP 002 00 WP 211 00

3.


4.



Acetone Marking Pen

GE Spec. D50TF13 Sharpie T.E.C. or Action Marker RTV 106 - Red

Silicon Rubber Adhesive 5.

WP 430 00





Variable Stator Vane Shroud Removal. a.


b.

Remove high pressure compressor (HPC) stator casings per WP 211 00. CAUTION FORWARD AND AFT HALVES OF EACH VSV SHROUD SEGMENT ARE MACHINED AS SETS AND HAVE SAME SERIAL NUMBER. THESE SEGMENTS SHALL BE MAINTAINED AS MATCHED SETS, OR BINDING OF VSV SYSTEM AND COMPRESSOR STALL MAY OCCUR. NOTE There are two VSV shrouds for each stage, one on each HPC stator casing half. Removal procedure is same for both.

c.

Position mark aft and forward inlet guide vane (IGV) shrouds (7 and 8, figure 1), aft and forward stage 0 shrouds (11 and 12), aft and forward stage 1 shrouds (13 and 14), and aft and forward stage 2 shrouds (16 and 17) for reinstallation.

d.

Remove aft and forward IGV shrouds (7 and 8) as follows: CAUTION DO NOT TURN BODY BOUND BOLTS THAT CONNECT FORWARD IGV SHROUD TO AFT IGV SHROUD OR DAMAGE TO IGV SHROUD SHALL OCCUR. (1)

Remove self-locking nuts (6) and shear bolts (9) that secure forward IGV shroud (8) and aft IGV shroud (7) together. Retain self-locking nuts and shear bolts for reinstallation. Separate and remove IGV shrouds. NOTE

IGV bushing may be retained in forward or aft IGV shroud. (2)

Remove IGV bushing (5) from each IGV (1) trunnion. Retain for reinstallation.




Figure 1. VSV Shrouds (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. VSV Shrouds (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Remove aft and forward stage 0 shrouds (11 and 12) as follows: CAUTION DO NOT TURN BODY BOUND BOLTS THAT CONNECT FORWARD STAGE 0 SHROUD TO AFT STAGE 0 SHROUD OR DAMAGE TO STAGE 0 SHROUD SHALL OCCUR. (1)

Remove self-locking nuts (6) and shear bolts (9) that secure forward stage 0 shroud (12) and aft stage 0 shroud (11) together. Retain self-locking nuts and shear bolts for reinstallation. Separate and remove stage 0 shrouds. NOTE

Stage 0 vane bushing may be retained in forward or aft stage 0 shroud. (2) f.

Remove stage 0 vane bushing (10) from each stage 0 vane (2) trunnion. Retain for reinstallation.


Remove self-locking nuts (6) and shear bolts (9) that secure forward stage 1 shroud (13) and aft stage 1 shroud (14) together. Retain self-locking nuts and shear bolts for reinstallation. Separate and remove stage 1 shrouds. NOTE

Stage 1 vane bushing may be retained in forward or aft stage 1 shroud. (2) g.



Remove self-locking nuts (6) and shear bolts (9) that secure forward stage 2 shroud (16) and aft stage IGV shroud (17) together. Retain self-locking nuts and shear bolts for reinstallation. Separate and remove stage 2 shrouds.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE IGV bushing may be retained in forward or aft IGV shroud. (2) h. 7.


Inspect VSV shrouds per WP 430 00.

Variable Stator Vane Shroud Installation. CAUTION ALL FORWARD AND AFT VSV SHROUDS ARE MACHINED AS SETS AND SHALL NOT BE INTERMIXED. IF FORWARD OR AFT HALF OF SHROUD REQUIRES REPLACEMENT, BOTH HALVES SHALL BE REPLACED. NOTE There are two VSV shrouds for each stage, one on each HPC stator casing half. Installation procedure is same for both. a.

Install aft and forward stage 2 variable stator vane shrouds as follows: (1)

Install stage 2 vane bushings (18, figure 1) onto stage 2 vanes (4) trunnions.

(2)

Align aft and forward stage 2 shrouds (16 and 17) so stage 2 vane bushings are in line with receptacles in shroud segments. CAUTION

DO NOT TURN BODY BOUND BOLTS THAT CONNECT FORWARD STAGE 2 SHROUD TO AFT STAGE 2 SHROUD OR DAMAGE TO STAGE 2 SHROUD SHALL OCCUR. (3)

Using shear bolts (9), bolthead forward, and self-locking nuts (6), secure forward stage 2 shroud (17) to aft stage 2 shroud (16). Tighten self-locking nuts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. Replace self-locking nut if running torque exceeds 3.5 lb in. (0.39 N⋅m) of torque.




ACETONE: EXPLOSIVE WHEN SUBJECTED TO HIGH TEMPERATURE, SOURCE OF IGNITION, HIGH PRESSURE, OR OTHER CHEMICALS. FLAMMABLE NEAR SPARKS, OPEN FLAMES, WELDING AREAS, HOT SURFACES, OTHER SOURCES OF IGNITION, OR WHILE SMOKING. INHALATION, CONTACT, OR INGESTION MAY CAUSE IRRITATION OR BURNING OF RESPIRATORY SYSTEM, EYES, FACE, SKIN, OR DIGESTIVE SYSTEM. PERSONAL PROTECTIVE EQUIPMENT REQUIRED WHEN HANDLING OR USING THIS MATERIAL. MAY LEAD TO ALLERGIC SENSITIVITY IN SOME INDIVIDUALS. THERMAL DECOMPOSITION MAY RELEASE TOXIC BY-PRODUCTS. PROVIDE LOCAL EXHAUST OR GENERAL DILUTION VENTILATION TO MEET PUBLISHED EXPOSURE LIMITS. IF THESE ARE NOT AVAILABLE, USE RESPIRATOR HAVING NIOSH APPROVAL FOR THE MATERIALS RELEASED. (4)

Clean shear bolts (9) threads and self-locking nut (6) ends with acetone. WARNING

VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELL-VENTILATED AREA (5) b.

Using RTV 106, cover self-locking nut (6) and all exposed shear bolt (9) threads.

Install stage 1 variable stator vane shroud as follows: (1)

Install stage 1 vane bushings (15) onto stage 1 vanes (3) trunnions.

(2)



Using shear bolts (9), bolthead forward, and self-locking nuts (6), secure forward stage 1 shroud (13) to aft stage 1 shroud (14). Tighten self-locking nuts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. Replace self-locking nut if running torque exceeds 3.5 lb in. (0.39 N⋅m) of torque.

(4)

Clean shear bolts (9) threads and self-locking nut (6) ends with acetone.

(5)





Install stage 0 variable stator vane shroud as follows: (1)

Install stage 0 vane bushings (10) onto stage 1 vanes (2) trunnions.

(2)



Using shear bolts (9), bolthead forward, and self-locking nuts (6), secure forward stage 0 shroud (12) to aft stage 0 shroud (11). Tighten self-locking nuts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. Replace self-locking nut if running torque exceeds 3.5 lb in. (0.39 N⋅m) of torque. WARNING



VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELL-VENTILATED AREA (5) d.


Install stage IGV variable stator vane shroud as follows: (1)

Install IGV bushings (5) onto IGV (1) trunnions.

(2)

Align aft and forward IGV shrouds (7 and 8) so IGV bushings are in line with receptacles in shroud segments. 9




DO NOT TURN BODY BOUND BOLTS THAT CONNECT FORWARD IGV SHROUD TO AFT IGV SHROUD OR DAMAGE TO IGV SHROUD SHALL OCCUR. (3)

Using shear bolts (9), bolthead forward, and self-locking nuts (6), secure forward stage IGV shroud (8) to aft stage IGV shroud (7). Tighten selflocking nuts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. Replace self-locking nut if running torque exceeds 3.5 lb in. (0.39 N⋅m) of torque. WARNING



VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELL-VENTILATED AREA (5)


e.

For IGV through stage 2, apply torque to move actuation ring segments +/- 5 degrees in open and closed direction. Torque shall be no greater than 140 lb in. (15.8 N⋅m) of torque.

f.

Install HPC stator casings onto engine per WP 211 00. CAUTION RTV ADHESIVE SHALL CURE FOR MINIMUM OF 8 HOURS BEFORE ENGINE TEST.

g.

Motor and test engine per GEK 105054, Volume 1, Chapter 7.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR FIXED STATOR VANE REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Compressor Fixed Stator Vane Installation. ............................................ High Pressure Compressor Fixed Stator Vane Removal. .................................................

4 3


GEK 105054 Volume II WP 214 00 1.


Introduction. This work package contains instructions for removal and installation of high pressure compressor (HPC) fixed stator vanes.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices High Pressure Compressor Stator Casings Replacement High Pressure Compressor Stator Casings Inspection Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 211 00 WP 423 00 GEK 105055


Part No.

Driver Set-Compressor Stator Vane Seating Tool, Vane Liner, Compressor Stator Case - Front & Rear Seating Tool, Vane Liner, Compressor Stator Case - Front & Rear Seating Tool, Vane Liner, Compressor Stator Case - Front & Rear Seating Tool, Vane Liner, Compressor Stator Case - Front & Rear Rod, Steel 0.400-0.405 in (10.17-10.29 mm) Dia

2C6019G01

2C7373G03 2C7373G05 2C7373G06 Local Purchase



Anti-Seize Compound

Milk of Magnesia (Unflavored) Fed Spec TT-I-735 736L680G01 R297P04 (Alt) GE Spec A50TF201 or MIL-T-5544

Isopropyl Alcohol Safety Cable Safety Wire Thread Lubricant 5.

2C7373G01


IPB Figure No./Item

Dovetail Liner Dovetail Liner Case Key Case key Metal O-Ring Gasket

13-3 13-4 13-19 13-18 13-11




High Pressure Compressor Fixed Stator Vane Removal. a.


b.

Remove HPC stator casings per WP 211 00. NOTE

•

Borescope plugs for HPC stages 7 through 11 and stages 13 and 14 are located in upper aft HPC stator casing.

•

Borescope plugs for HPC stages 12 and 15 are located in lower aft HPC stator casing.

c.

Remove safety wire and remove all borescope plugs in HPC stator casings. Remove and discard metal gaskets, where applicable.

d.

Remove HPC fixed stator vanes as follows: NOTE Only upper HPC stator casings have case keys. (1)

Remove case keys from upper forward and aft HPC stator casing horizontal flanges. CAUTION

ENSURE DRIVER, 2C6019, SEATS AGAINST HPC FIXED STATOR VANE PLATFORM AND NOT AIRFOIL. NOTE

e.

•

Use driver, 2C6019P02, for HPC fixed stator vanes in stages 7 through 15.

•

Use driver, 2C6019P04, for HPC fixed stator vanes in stage 16.

(2)

Slide HPC fixed stator vanes out of dovetail grooves. If necessary, use driver, 2C6019, to remove binding HPC fixed stator vanes.

(3)

If installed, remove vane dovetail liners from HPC stator stages 12 through 15 dovetail grooves.

Inspect HPC stator casings per WP 423 00.


GEK 105054 Volume II WP 214 00 7.


High Pressure Compressor Fixed Stator Vane Installation. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. a.

Clean all internal and external surfaces, dovetail grooves, and holes with isopropyl alcohol. NOTE When used, HPC stator casing requires four dovetail liners per stage, two left-hand and two right-hand.

b.

If required, install dovetail liners into HPC stator casing stages 12 through 15 dovetail grooves as follows: (1)

Position aft HPC stator casing on workbench, aft end down.

(2)

Apply thread lubricant to dovetail grooves.

(3)

Install dovetail liners with longer cross section legs into forward dovetail groove.

(4)

Install dovetail liners with shorter cross section legs into aft dovetail groove.

(5)

Install one HPC fixed stator vane into dovetail groove. NOTE

•

Use seating tool, 2C7373G01, for HPC fixed stage 12 stator vanes.

•


•


•


(6)

Using seating tool, 2C7373, and plastic mallet, drive HPC fixed stator vane to vertical centerline.

(7)

Trim excess length of dovetail liners flush with horizontal flanges.




c.

•


•


•

Ensure locking HPC fixed stator vanes are installed only at upper HPC stator casing horizontal split-line flange locations.

Install HPC fixed stator vanes into upper HPC stator casing as follows: (1)

Install locking HPC fixed stator vane flush with horizontal casing flange. CAUTION

ENSURE DRIVER, 2C6019, SEATS AGAINST HPC FIXED STATOR VANE PLATFORM AND NOT AIRFOIL. OTHERWISE, DAMAGE MAY RESULT. NOTE

•


•


(2)

Using thread lubricant, coat dovetails of applicable number of HPC fixed stator vanes for stage being installed.

(3)

Install non-locking HPC fixed stator vane into dovetail groove. Push vane through dovetail groove until seated against locking HPC fixed stator vane. Use driver, 2C6019, if necessary, to aid in moving HPC fixed stator vanes that bind in dovetail grooves. NOTE

HPC fixed stator vanes with wide platforms may be intermixed with narrow platform vanes to place borescope access vanes in proper location. (4)

Continue to install non-locking HPC stator fixed vanes into dovetail groove. If applicable, ensure borescope access vanes are installed with cutouts in vanes aligned for borescope access. NOTE

Refer to table 1 for number of HPC fixed stator vanes per stage. (5)

Install applicable number of non-locking HPC fixed stator vanes for stage.

(6)

Install locking vane flush with HPC stator casing horizontal split-line flange.


GEK 105054 Volume II WP 214 00 (7)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Measure gap between last non-locking HPC fixed stator vane and locking HPC fixed stator vane. Gap shall meet circumferential gap requirement for stage per table 1. Table 1. Fixed Vane Quantity/Width Clearances Tip Shake

Minimum Platform Width Inch (mm)

Circumferential Clearance Each Casing Half Inch (mm)

Stage

Vane Qty

Inch

7

72

0-0.040

(0-1.02)

1.1555

(29.350)

0.090-0.130

(2.29-3.30)

8 9

68

0-0.020

(0-0.51)

1.2235

(31.077)

0.105-0.145

(2.67-3.68)

76

0-0.030

(0-0.76)

1.094

(27.79)

0.105-0.145

(2.67-3.68)

10

80

0-0.030

(0-0.76)

1.039

(26.39)

0.115-0.155

(2.92-3.94)

11

80

0-0.030

(0-0.76)

1.039

(26.39)

0.120-0.160

(3.05-4.06)

12

80

0-0.020

(0-0.51)

1.0391

(26.393)

0.040-0.080

(1.02-2.03)

13

80

0-0.020

(0-0.51)

1.0391

(26.393)

0.044-0.084

(1.12-2.13)

14

88

0-0.020

(0-0.51)

0.9415

(23.914)

0.047-0.087

(1.20-2.21)

15

88

0-0.020

(0-0.51)

0.9352

(23.754)

0.050-0.090

(1.27-2.29)

16

102

0-0.020

(0-0.51)

0.7445

(18.91)

0.050-0.090

(1.27-2.29)

(8)

(mm)

If locking HPC fixed stator vane protrudes above HPC stator casing horizontal split-line flange, perform following steps: (a) Remove locking HPC fixed stator vane. NOTE

HPC fixed stator vane platforms may be stoned down to minimum width defined in table 1, provided surface finish is 63 or better and corner edge breaks are 0.005 in. (0.13 mm) minimum. (b) Replace non-locking vanes with wide and narrow platform vanes until locking HPC fixed stator vane will fit flush with or below HPC stator casing split-line flange. (c) Install locking HPC fixed stator vane. (d) Measure gap between last HPC fixed stator vane and HPC stator casing horizontal split-line flange. Gap shall meet circumferential gap requirement for stage per table 1. d.

Install HPC fixed stator vanes in lower HPC stator casing as follows: (1)

Install and hold HPC fixed stator vane flush with horizontal casing flange.




Clamp parallel bar flush with HPC stator casing horizontal split-line flange.

(3)

Push installed HPC fixed stator vane against parallel bar.

(4)

Using thread lubricant, coat dovetails of applicable number of HPC fixed stator vanes for stage being installed. CAUTION

ENSURE DRIVER, 2C6019, SEATS AGAINST HPC FIXED STATOR VANE PLATFORM AND NOT AIRFOIL. NOTE

•


•


(5)

Install HPC fixed stator vane into dovetail groove. Push vane through dovetail groove until seated against installed HPC fixed stator vane. Use driver, 2C6019, if necessary, to aid in moving HPC fixed stator vanes that bind in dovetail grooves. NOTE

HPC fixed stator vanes with wide platforms may be intermixed with narrow platform vanes to place borescope access vanes in proper location. (6)

Continue to install HPC stator fixed vanes into dovetail groove. If applicable, ensure borescope access vanes are installed with cutouts in vanes aligned for borescope access. NOTE

Refer to table 1 for number of HPC fixed stator vanes per stage. (7)

Install applicable number of HPC fixed stator vanes for stage.

(8)

Measure gap between last HPC fixed stator vane and HPC stator casing horizontal split-line flange. Gap shall meet circumferential gap requirement for stage per table 1.

(9)

If HPC fixed stator vane protrudes above HPC stator casing horizontal split-line flange, perform following steps: (a) Remove HPC fixed stator vane.




HPC fixed stator vane platforms may be stoned down to minimum width defined in table 1, provided surface finish is 63 or better and corner edge breaks are 0.005 in. (0.13 mm) minimum. (b) Replace HPC fixed stator vanes with wide and narrow platform vanes until HPC fixed stator vane will fit flush with or below HPC stator casing splitline flange. (c) Measure gap between last HPC fixed stator vane and HPC stator casing horizontal splitline flange. Gap shall meet circumferential gap requirement for stage per table 1. NOTE

•

Borescope plugs for HPC stages 7 through 11 and stages 13 and 14 are located in upper HPC stator casing.

•

Borescope plugs for HPC stages 12 and 15 are located in lower aft HPC stator casing.

•

Rod simulates borescope and shall pass freely through HPC stator casing and HPC fixed stator vane platforms.

e.

Insert 0.400-0.405 inch (10.16-10.29 mm) diameter rod through borescope ports of stages 7 through 15. If necessary, rearrange HPC fixed stator vanes to permit insertion of rod.

f.

Install borescope plugs as follows:

g.

(1)

Install metal gasket onto borescope plug for HPC stages 12, 14, and 15.

(2)

Using anti-seize compound, lubricate case bore prior to installing borescope plugs.

(3)

Install stages 7 through 11 borescope plugs into HPC stator casing. Tighten borescope plugs to 40-60 lb in. (4.6-6.7 N⋅m) of torque and safety wire.

(4)

Install stages 12, 14, and 15 borescope plugs into HPC stator casing. Tighten borescope plugs to 80-100 lb in. (9.1-11.3 N⋅m) of torque and safety wire.

Measure each vane tip shake. See table 1 for limits.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines NOTE Chamfer side of key goes into HPC stator casing. Flat end of key shall not extend beyond HPC stator casing flange mating surface. h.

Install casing keys into slot at each horizontal flange of upper HPC stator casing.

i.

Secure casing keys as follows:

j.

(1)

Secure casing keys in front upper casing by staking each key two places adjacent to casing flange at four locations at each end, between stages 7 and 8 and between stages 9 and 10.

(2)

Secure casing keys to rear upper casing by staking each key two places adjacent to casing flange near each end of keys and midway between stages 13 and 14 vane slots.

Install HPC stator casings per WP 211 00.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR ROTOR BLADES REPLACEMENT (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 19 ................. 1 20 Blank ........... 1 Alphabetical Index Subject

Page

High Pressure Compressor Rotor Stage 0 Blisk Replacement. ........................................ 3 High Pressure Compressor Rotor Stage 1 Blade Replacement. ....................................... 3 High Pressure Compressor Rotor Stage 2 Blade Replacement. ....................................... 8 High Pressure Compressor Rotor Stages 3 Through 16 Blade Replacement. ................. 11


1

GEK 105054 Volume II WP 215 00 1.


Introduction. This work package contains instructions for removal and installation of high pressure compressor (HPC) rotor blades. Instructions for blade selection and tip shake limits are included. In addition, recommended methods for repair of HPC rotor blades are covered.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices High Pressure Compressor Stator Casings Replacement Gas Generator Assembly Replacement

GEK 105054 WP 002 00 WP 211 00 WP 301 00


Part No.

Program, Computer Airfoil Balancing Tool Set, Remove High Pressure Compressor Rotor Stage 1 and 2 Retaining Ring Driver Set, Compressor Stator Vane Program, Balance - Blade Installation/Replacement

BLADEOPT



Penetrating Oil Marking Pen

GE Spec A50TF54 Sharpie T.E.C. or Action marker Fed Spec VV-P-236

Soft Petrolatum 5.

2

1C8312G01 2C6019G01 9446M61G01





High Pressure Compressor Rotor Stage 0 Blisk Replacement. a.

7.

HPC stage 0 blisk is nonreplaceable at field level.

High Pressure Compressor Rotor Stage 1 Blade Replacement. a.


b.

Remove HPC forward upper stator casing per WP 211 00. CAUTION TO AVERT POSSIBILITY OF HPC ROTOR IMBALANCE, POSITION MARK ALL BLADES AS THEY ARE REMOVED SO THEY CAN BE RETURNED TO THEIR ORIGINAL POSITION.

c.

Using marking pen, mark HPC rotor stage 1 blades (3, figure 1) as to HPC rotor stage 1 disk (2) location.

d.

Using tool set, 1C8312, remove HPC stage 1 rotor blades (3) as follows: CAUTION USE CARE DURING REMOVAL OF RETAINING RING TO PREVENT DAMAGE TO HPC ROTOR STAGE 1 DISK OR SEALS. (1)

Remove HPC retaining ring (1) on forward side of HPC rotor stage 1 disk (2) as follows: (a) Locate slit in retaining ring (1). (b) Select tool labeled for use with HPC rotor stage 1 disk. (c) Position hook portion of tool (figure 2) toward retaining ring. (d) Place one finger of hook between split in retaining ring. (e) Rotate tool handle to bring other finger of hook against underside of other end of retaining ring. (f) Continue to rotate tool handle in same direction to pull retaining ring end out of slot and away from face of HPC rotor stage 1 disk. (g) Position nylon pry bar behind retaining ring to hold it away from HPC rotor stage 1 disk. (h) Using second nylon pry bar, work around HPC rotor to remove retaining ring.


3



Figure 1. HPC Rotor Stages 1 and 2 4




Figure 2. HPC Rotor Stages 1 and 2 Retaining Ring Removal Tool Set Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

5



USE CARE DURING REMOVAL OF HPC ROTOR STAGE 1 BLADES TO PREVENT DAMAGE TO HPC ROTOR STAGE 1 DISK OR SEALS. (2)

Push HPC rotor stage 1 blade (3) radially inward.

(3)

Slide HPC rotor stage 1 blade (3) out forward side of HPC rotor stage 1 disk (2).

(4)

Place HPC rotor stage 1 blade (3) into approved container.

(5)

Repeats substeps (3) through (5) as required for HPC rotor stage 1 blades (3) requiring replacement. NOTE

e.

•

HPC rotor stage 1 blades not being replaced shall be installed in position from which they were removed to maintain HPC rotor balance.

•

Length of replacement blades shall not exceed length of adjacent blades.

Use following criteria to select replacement HPC rotor stage 1 blades. (1)

Any HPC rotor stage 1 blade may be replaced by HPC rotor stage 1 blade of equal weight.

(2)

Up to 100 percent of HPC rotor stage 1 blades may be blended locally for erosion at tips, if all HPC rotor stage 1 blades are blended by approximately same amount.

(3)

If all stage 1 blades will be replaced, calculate the blade positions with the blade installation/replacement balance program, 9446M61G01.

(4)

If portion of HPC rotor stage 1 blade, other than tip, is missing: (a) Weigh eight replacement HPC rotor stage 1 blades.

6




Figure 3. HPC Blade Replacement Guide Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

7


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (b) Use average weight of eight replacement HPC rotor stage 1 blades as replacement HPC rotor stage 1 blade weight required.

(5) f.

HPC rotor stage 1 blades may be replaced by using HPC blade replacement guide (figure 3).

Install HPC rotor stage 1 blades (3, figure 1) as follows: (1)

Install protector over seals on HPC rotor stage 1 disk (2) and HPC rotor stage 2 disk (6).

(2)

Slide HPC rotor stage 1 blade (3) into HPC rotor stage 1 disk (2) dovetail from forward side of HPC rotor stage 1 disk.

(3)

Repeats substeps (1) and (2) for all replaced HPC rotor stage 1 blades (3) removed.

(4)

Pull HPC rotor stage 1 blade (3) radially outward.

(5)

Install retaining ring (1) onto forward side of HPC rotor stage 1 disk (2).

(6)

Visually inspect retaining ring (1) for proper seating as follows: (a) Ensure retaining rings are engaged in grooves on HPC rotor stage 1 disk (2) for complete 360 degree rotation. (b) Ensure gap in retaining ring is located over HPC rotor stage 1 disk post.

8.

High Pressure Compressor Rotor Stage 2 Blade Replacement. a.


b.

Remove HPC stator casings per WP 211 00. CAUTION TO AVERT POSSIBILITY OF HPC ROTOR IMBALANCE, POSITION MARK ALL BLADES AS THEY ARE REMOVED SO THEY CAN BE RETURNED TO THEIR ORIGINAL POSITION.

c.

8

Using marking pen, mark HPC rotor stage 2 blades (7, figure 1) as to HPC rotor stage 2 disk (6) location.




Using tool set, 1C8312, remove HPC rotor stage 2 blades (7) as follows: CAUTION USE CARE DURING REMOVAL OF RETAINING RING TO PREVENT DAMAGE TO HPC ROTOR STAGE 2 DISK OR SEALS. (1)

Remove HPC retaining ring (5) on forward side of HPC rotor stage 2 disk (6) as follows: (a) Locate slit in retaining ring (5). (b) Select tool labeled for use with HPC rotor stage 2 disk. (c) Position hook portion of tool (figure 2) toward retaining ring. (d) Place one finger of hook between split in retaining ring. (e) Rotate tool handle to bring other finger of hook against underside of other end of retaining ring. (f) Continue to rotate tool handle in same direction to pull retaining ring end out of slot and away from face of HPC rotor stage 2 disk. (g) Position nylon pry bar behind retaining ring to hold it away from HPC rotor stage 2 disk. (h) Using second nylon pry bar, work around HPC rotor to remove retaining ring. CAUTION

USE CARE DURING REMOVAL OF HPC ROTOR STAGE 2 BLADES TO PREVENT DAMAGE TO HPC ROTOR STAGE 2 DISK OR SEALS. (2)

Push HPC rotor stage 2 blade (7) radially inward.

(3)

Slide HPC rotor stage 2 blade (7) out forward side of HPC rotor stage 2 disk (6).

(4)

Place HPC rotor stage 2 blade (7) into approved container.

(5)

Repeats substeps (3) through (5) as required for HPC rotor stage 2 blades (7) requiring replacement.


9



e.

•

HPC rotor stage 2 blades not being replaced shall be installed in position from which they were removed to maintain HPC rotor balance.

•

Length of replacement blades shall not exceed length of adjacent blades.

Use following criteria to select replacement HPC rotor stage 2 blades. (1)

Any HPC rotor stage 2 blade may be replaced by HPC rotor stage 2 blade of equal weight.

(2)

Up to 100 percent of HPC rotor stage 2 blades may be blended locally for erosion at tips, if all HPC rotor stage 2 blades are blended by approximately same amount.

(3)

When no part of HPC rotor stage 2 blade, other than tip, is missing, use BLADEOPT computer program to determine replacement blade location.

(4)

If portion of HPC rotor stage 2 blade, other than tip, is missing: (a) Weigh eight replacement HPC rotor stage 2 blades. (b) Use average weight of eight replacement HPC rotor stage 2 blades as replacement HPC rotor stage 2 blade weight required.

(5) f.

HPC rotor stage 2 blades may be replaced by using HPC blade replacement guide (figure 3).

Install HPC rotor stage 2 blades (7, figure 1) as follows: (1)

Install protector over seals on HPC rotor stage 2 disk (6) and HPC rotor spool (6, figure 4).

(2)

Apply a small amount of soft petrolatum to the RTV beads on the dovetail of stage 2 blade (7) to aid in sliding the blade into the stage 2 disk (6).

(3)

Slide HPC rotor stage 2 blade (7, figure 1) into HPC rotor stage 2 disk (6) dovetail from forward side of HPC rotor stage 2 disk.

(4)

Repeats substeps (1) through (3) for all replaced HPC rotor stage 2 blades (7).

(5)

Pull HPC rotor stage 2 blade (7) radially outward.

(6)

Install retaining ring (5) onto forward side of HPC rotor stage 2 disk (6) with double hump side facing forward.

(7)

Visually inspect retaining ring (5) for proper seating as follows: (a) Ensure retaining rings are engaged in grooves on HPC rotor stage 2 disk (6) for complete 360 degree rotation.

10



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (b) Ensure gap in retaining ring is located over HPC rotor stage 2 disk post. (8) 9.


High Pressure Compressor Rotor Stages 3 Through 16 Blade Replacement. a.


b.

Remove HPC stator casings per WP 211 00. CAUTION TO AVERT POSSIBILITY OF HPC ROTOR IMBALANCE, POSITION MARK ALL BLADES AS THEY ARE REMOVED SO THEY CAN BE RETURNED TO THEIR ORIGINAL POSITION. NOTE For HPC rotor stages 3 through 16, removal, replacement selection, and installation is same for all stages.

c.

Using marking pen, mark HPC rotor blade (1, 3, or 5, figure 4) as to HPC rotor spool (6) location. CAUTION PENETRATING OIL WD40 SHALL NOT BE USED ON GAS GENERATOR OR GAS TURBINE. LIQUID WRENCH NO. 1 IS AN APPROVED SUBSTITUTE. NOTE

d.

•

To aid loosening of setscrew in locking lugs, apply penetrating oil and allow to soak. Tap lightly on Allen wrench inserted into hex opening of setscrew to jar threads of setscrew.

•

If only a few HPC rotor blades require replacement, it is not necessary to remove all HPC rotor blades of a stage. After loosening locking lugs, rotate entire stage of HPC rotor blades until damaged blades can be removed from entry slot. Mark position of entry slot.

•

Use nylon drift to aid in rotation of HPC rotor blades for stages 3 through 6.

•

Use compressor stator vane driver set, 2C6019, to aid in rotation of HPC rotor blades for stages 7 through 16.

Remove HPC rotor blades (5) and locking HPC rotor blades (1 and 3) as follows: (1)

Using long T-handled Allen wrench, turn setscrews counterclockwise (CCW) to loosen setscrews of two locking lugs (2) until locking lugs slip below surface of retaining groove in HPC rotor spool (6). Change 1


11



Figure 4. HPC Rotor Assembly (Sheet 1 of 2) 12




Figure 4. HPC Rotor Assembly (Sheet 2 of 2) (2)

Rotate entire stage of HPC rotor blades (5) circumferentially in either direction, approximately 50 percent of HPC rotor blade base width.

(3)

Pull locking HPC rotor blade (1 or 3) straight out of entry slot in HPC rotor spool (6).

(4)

Place locking HPC rotor blade (1 or 3) into approved container.

(5)

Slide locking lug (2) over to entry slot in HPC rotor spool (6) and remove. NOTE

•

Ensure HPC rotor blades are position marked so they may be reinstalled into position from where they were removed.

•

Balance weights are installed at various points between HPC rotor blades. If removed, they shall be marked for installation in same positions.

(6)

Continue to remove HPC rotor blades (5) as necessary. Slide HPC rotor blades to entry slot in HPC rotor spool (6) and lift out. Place HPC rotor blades into approved container.

(7)

Remove balance weights (4) as required. Position mark balance weights prior to placing in approved container. Change 1


13



Using blade installation/replacement balance program, 9446M61G01, computer program and following criteria, select replacement HPC rotor blades. (1)

Up to 25 percent of HPC rotor blades in HPC rotor, or three complete stages of HPC rotor blades, may be replaced if: (a) All balance weights and unchanged HPC rotor blades removed during replacement of HPC rotor blades are returned to their original locations. (b) Damaged HPC rotor stage 3 blades are replaced with HPC rotor stage 3 blades of same weight, where possible, within 0.016 oz (0.5 gr). (c) Damaged HPC rotor stages 4 and 5 blades are replaced with HPC rotor stages 4 and 5 blades of same weight, where possible, within 0.010 oz (0.3 gr). (d) Damaged HPC rotor stages 6 through 16 blades are replaced with HPC rotor stages 6 through 16 blades of same weight, where possible, within 0.007 oz (0.2 gr). (e) Heavily damaged HPC rotor blades, with pieces missing, shall be replaced with HPC rotor blades of same part number.

(2)

Ten blades in HPC rotor may be reworked to maximum repairable limits, if reworked HPC rotor blades are distributed uniformly around circumference to reduce imbalance effects. NOTE

It is recommended that equivalent of no more than 50 percent of stages be blended to minimum tip-chord erosion limits (3)

14

Up to 100 percent of HPC rotor stages 3 through 16 blades may be blended locally for erosion at tips, if all HPC rotor blades in affected stage are blended by approximately same amount.




Install HPC rotor blades (5) and locking HPC rotor blades (1 and 3) as follows: NOTE Locking slots in HPC rotor spool will not be visible after HPC rotor blades are installed. (1)

Mark locking slots onto outside diameter (OD) of HPC rotor spool (6) at each stage. NOTE

•

Each stage shall contain total number of HPC rotor blades listed in table 1.

•

HPC rotor blades have narrow or wide platforms. They may be used interchangeably to meet accumulated clearance limits.

•

All HPC rotor blade platforms, except those of locking blades, may be stoned. Overlapping of blade platforms (shingling) is not permitted.

•

Install wide platform blades last to obtain required clearance.

•


•


(2)

If HPC rotor blade platforms need to be stoned, following steps apply: (a) Measure blade platform width before and after stoning. (b) Blade platforms may be stoned to minimum width AH listed in table 1. (c) Remove material equally along entire platform-length and approximately equal amount from each side of platform. (d) Surface finish shall be 63 or better and corner edge break shall be 0.005 in. (0.13 mm) minimum.

(3)

Insert HPC rotor blade (5), according to position mark made during HPC rotor blade removal, into entry slot.

(4)

Slide HPC rotor blade circumferentially into retaining groove.


15


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Rotor Blade Installation Guide

16

Dim D

Cumulative tip blend length allowed per stage

Dimension AH measured at center of platform

Stage

Number of Blades

3

42

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.4 in. (86.4 mm)

4

45

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

5

48

0.001 in. (0.03 mm)

6

54

7

Minimum Maximum

Initially install following number of narrow and wide platform blades into each stage: Wide

Narrow

1.265 in. (32.13 mm)

19

19

3.4 in. (86.4 mm)

1.264 in. (32.11 mm)

16

25

0.014 in. (0.35 mm)

3.4 in. (86.4 mm)

1.255 in. (31.88 mm)

15

29

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.5 in. (88.9 mm)

1.161 in. (29.49 mm)

18

32

56

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.4 in. (86.4 mm)

1.152 in. (29.26 mm)

16

36

8

64

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.4 in. (86.4 mm)

1.035 in. (26.29 mm)

14

46

9

66

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.6 in. (91.4 mm)

1.073 in. (26.25 mm)

10

52

10

66

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.6 in. (91.4 mm)

1.060 in. (26.92 mm)

16

46

11

76

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.8 in. (96.5 mm)

0.937 in. (23.80 mm)

10

62

12

76

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.8 in. (96.5 mm)

0.953 in. (24.21 mm)

10

62

13

76

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.8 in. (96.5 mm)

0.964 in. (24.49 mm)

10

62

14

76

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.6 in. (91.4 mm)

0.975 in. (24.77 mm)

10

62

15

76

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.6 in. (91.4 mm)

0.978 in. (24.84 mm)

10

62

16

76

0.001 in. (0.03 mm)

0.014 in. (0.35 mm)

3.6 in. (91.4 mm)

0.978 in. (24.84 mm)

10

62




Install balance weights (4) to same position according to position marks made during removal.

(6)

Continue to install HPC rotor blades (5) until four HPC rotor blade locations remain.

(7)

Install locking HPC rotor blade (1 or 3) into entry slot and slide toward locking slot in HPC rotor spool (6). Ensure cutout on locking HPC rotor blade base faces entry slot.

(8)

Install locking HPC rotor blade (1 or 3) into entry slot and slide toward other locking slot in HPC rotor spool (6). Ensure cutout on locking HPC rotor blade base faces entry slot.

(9)

Install two locking lugs (2) into entry slot and position each against locking HPC rotor blade (1 and 3). Ensure slope of locking lug follows slope of HPC rotor spool (6). Locking lug setscrew shall be retracted.

(10) Install another locking HPC rotor blade (1 or 3). Ensure cutout in locking HPC rotor blade base faces locking lug (2). NOTE

•

Use nylon drift to aid in rotation of HPC rotor blades for stages 3 through 6.

•

Use compressor stator vane driver set, 2C6019, to aid in rotation of HPC rotor blades for stages 7 through 16.

(11) Rotate entire stage of HPC rotor blades (5) and locking HPC rotor blades (1 and 3) circumferentially, approximately 50 percent of blade base width, until last HPC rotor blade can be installed. (12) Install locking HPC rotor blade (1 or 3). Ensure cutout in locking HPC rotor blade base faces locking lug (2). NOTE Locking slots in HPC rotor spool are at locations previously matchmarked. (13) Rotate entire stage of HPC rotor blades in opposite direction of rotation used in substep (11), until locking lugs (2) are aligned with locking slots in HPC rotor spool (6). (14) Turn setscrew to raise one locking lug (2) into locking slot in HPC rotor spool (6). Tighten setscrew to 8.0-9.0 lb in. (0.9-1.0 N⋅m) of torque. Top of locking lug shall be flush or below top of blade platform.


17



(15) Determine total accumulated clearance (Dim D) of HPC rotor blade platforms as follows: (a) Rotate HPC rotor blades (5) circumferentially, away from locking HPC rotor blade (1 or 3), to compress HPC rotor blades into one continuous group. (b) Form one gap between HPC rotor blade platforms for stage being checked. (c) Measure gap. Total accumulated clearance (Dim D) between HPC rotor blade platforms shall not exceed limits of table 1. (16) If Dim D limits are exceeded, replace HPC rotor blade (5) adjacent to locking HPC rotor blades (1 and 3) with wide platform HPC rotor blades. (17) Check each HPC rotor blade for overlap of blade platforms (shingling). Replace any HPC rotor blade exhibiting tendency to shingle. (18) Turn locking lug (2) setscrew to raise second locking lug into locking slot in HPC rotor spool (6) Tighten setscrews in both locking lugs as follows: (a) Tighten setscrews to 8-9 lb in. (0.9-1.0 N⋅m) above running torque. (b) Measure running torque just prior to seating (within one turn) of setscrew with dovetail slot bottom. (c) If running torque falls below 4 lb in. (0.5 N⋅m) of torque, measure breakaway torque. (d) Replace any locking lug (2) and/or setscrew when breakaway torque falls below 4 lb in. (0.5 N⋅m) after torquing. (e) Top of locking lug shall be flush or below top of blade platform. (19) Check blade tip shake at several places around each stage as follows: (a) Pull HPC rotor blade outward as far as possible and move blade tip at right angles to retaining slot. (b) Using dial indicator, measure HPC rotor blade tip shake. (c) HPC rotor blade tip shake shall meet limits shown in table 2.

18



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPC Rotor Blade Tip Shake Limits Stage 1 2 3 4-5 6 7 8-9 10-13 14-16 g.

Minimum 0.000 in. 0.010 in. 0.001 in. 0.001 in. 0.001 in. 0.001 in. 0.001 in. 0.001 in. 0.001 in.

Maximum 0.00 mm 0.25 mm 0.03 mm 0.03 mm 0.03 mm 0.03 mm 0.03 mm 0.03 mm 0.03 mm

Interference fit 0.290 in. 7.37 mm 0.110 in. 2.79 mm 0.095 in. 2.41 mm 0.085 in. 2.16 mm 0.075 in. 1.91 mm 0.070 in. 1.78 mm 0.060 in. 1.52 mm 0.050 in. 1.27 mm

Install the HPC upper stator casing. Refer to WP 211 00.

Change 1

19/(20 Blank)




WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR AND POWER TURBINE SEPARATION AND JOINING (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Gas Generator and Power Turbine Joining. ...................................................................... Gas Generator and Power Turbine Separation. ................................................................

9 3


GEK 105054 Volume II WP 216 00 1.


Introduction. This work package contains instructions for the separation and joining of LM2500+ Model PK gas generator and GE supplied six stage power turbine, using a maintenance dolly. For LM2500+ Model GK gas generator, consult packager’s manual. For LM2500+ Model GV gas generator and Model PV gas turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown, for further instructions.

2.


Title

For LM2500+ Model PK gas turbine: Operation and Maintenance Manual, Volume I GEK 105054 General Maintenance Practices Chapter 10 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Gas Turbine Outside Piping and Wiring Removal and Installation SWP 113 01 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Maintenance Dolly Usage WP 303 00 Gas Turbine Miscellaneous Sump Components Inspection SWP 413 01 For LM2500+ Model GV gas generator and Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

4.


Part No.

Mount Set, Ground Handling-Power Turbine Fixture, Lift-Power Turbine Assembly

1C8321G01 1C6955G03





Petrolatum Thread Lubricant 5.





Gas Generator and Power Turbine Separation. a.


b.

For retention of turbine mid frame (TMF) with gas generator, remove gas generator from power turbine per WP 301 00. NOTE If desired, the gas generator and power turbine can be separated in the maintenance dolly, with the TMF being retained on the power turbine.

c.

For retention of TMF with power turbine, remove gas generator from power turbine as follows: (1)

Remove gas turbine from enclosure per WP 300 00.

(2)

Install gas turbine into maintenance dolly, 1C9372, and adapter assembly 1C8302, per WP 303 00.

(3)

Disconnect external tubing and piping (figure 1) between power turbine and gas generator as follows: (a) Disconnect balance piston air tube at power turbine-TMF flange per SWP 113 01. (b) Disconnect D-sump vent air tube at power turbine-TMF flange per SWP 113 01. (c) Disconnect D-sump pressurization tube at power turbine-TMF flange per SWP 113 01. WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (d) Disconnect lube oil supply tube at power turbine-TMF flange per SWP 113 01. (e) Disconnect D-sump scavenge tube at power turbine-TMF flange per SWP 113 01.




Figure 1. External Piping and Wiring (Sheet 1 of 2) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. External Piping and Wiring (Sheet 2 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 216 00 (4)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Disconnect external piping and tubing between gas generator and TMF as follows: WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Disconnect C-sump oil supply tube from TMF strut cap per SWP 113 01. (b) Disconnect C-sump scavenge tube from TMF strut cap per SWP 113 01. (c) Disconnect B- and C-sump drain tube from TMF strut cap per SWP 113 01. (d) Disconnect five cooling air tubes from TMF strut caps per SWP 113 01. (e) Disconnect two HP recoup air manifolds from TMF per SWP 113 01. (5)

Install power turbine ground handling mount fixtures, 1C8321 (figure 2), onto power turbine as follows: CAUTION

DO NOT TURN BODY-BOUND BOLTS DURING REMOVAL, OR DAMAGE TO POWER TURBINE STATOR CASING MAY OCCUR. NOTE Boltholes are numbered forward moving aft. (a) Remove nine bolts, in boltholes 1 through 9, on both sides of horizontal split flange of power turbine stator case. Retain engine hardware for reinstallation. (b) Remove four bolts, washers, and nuts, on power turbine forward vertical flange, in boltholes immediately underneath both horizontal split-line flanges. Retain engine hardware for reinstallation.




Figure 2. Power Turbine Ground Handling Mount Fixtures, 1C8321 NOTE Ground handling mount fixtures, 1C8321, are marked as to which side of power turbine they are to be installed on. Ensure fixtures are installed onto lower side of horizontal split-line flange. (c) Using slave nuts and bolts, attach ground handling mount fixtures, 1C8321, onto power turbine. Tighten bolts to 70-110 lb in. (8.0-12.4 N⋅m) of torque. (6)

Install compressor rear frame (CRF) support jack assembly, 1C8333, onto maintenance dolly, 1C9372, per WP 303 00.

(7)

Install power turbine support posts, part of adapter set, 1C8302, onto maintenance dolly, 1C9372, per WP 303 00.

(8)

Engage power turbine support posts, part of adapter set, 1C8302, into power turbine ground handling mount fixtures, 1C8321, per WP 303 00.

(9)

Raise CRF support jack assembly, 1C8333, to engage and support CRF.

(10) Using marking pen, matchmark brackets on CRF aft flange and TMF forward flange. (11) Remove 136 bolts and self-locking nuts at CRF-TMF turbine flange. Remove brackets as securing hardware is removed. 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



(12) Install power turbine lift fixture, 1C6955 (figure 3), onto power turbine as follows: (a) Attach hoist to power turbine lift fixture, 1C6955, by engaging hoist hook in trolley clevis of lift fixture. (b) Position power turbine lift fixture, 1C6955, over power turbine assembly. (c) Lower power turbine lift fixture, 1C6955, until lift pins in legs of forward yoke align with forward holes in ground handling mount fixtures, 1C8321, on power turbine. (d) Slide lift pins into ground handling mount fixtures, 1C8321, on both sides of power turbine. (e) Lock slide bars into slots. Hand-tighten retainer screws that secure slide bar. (f) Using ball lock pins, attach aft brackets to ground handling mounts of TRF. NOTE Ensure weight of power turbine is supported by lift fixture, 1C6955, prior to disengaging power turbine support posts. (13) Disengage power turbine support posts, part of adapter set, 1C8302, from ground handling mount fixtures, 1C8321. (14) Disengage power turbine support posts, part of adapter set, 1C8302, from TRF ground handling mounts. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE POWER TURBINE MAINTAINS CORRECT ALIGNMENT WITH GAS GENERATOR DURING REMOVAL TO AVOID DAMAGE TO NO. 5 BEARINGS AND SEALS. (15) Using hoist and power turbine lift fixture, 1C6955, move power turbine aft to clear high pressure turbine (HPT) rotor aft shaft.




Figure 3. Lift Fixture, 1C6955 (16) Lift and remove power turbine from maintenance dolly, 1C9372, and gas generator. (17) Using four slave bolts, secure HPT stage 2 nozzle to CRF aft flange. Tighten bolts hand-tight. (18) Inspect No. 5 bearing and C-sump components per SWP 413 01. (19) Protect exposed No. 5 bearing components per GEK 105054, Chapter 10. (20) Cover or cap all piping and tubing openings. 7.

Gas Generator and Power Turbine Joining. a.

If TMF is installed on gas generator, join gas generator to power turbine per WP 301 00.

b.

If TMF is installed on power turbine, join gas generator to power turbine as follows: (1)

Remove four slave bolts that secure HPT stage 2 nozzle to CRF aft flange.





Using isopropyl alcohol, thoroughly clean CRF aft flange, HPT stage 2 nozzle flange, and TMF forward flange.

(3)

Uncover or uncap all piping and tubing openings. CAUTION

USE CAUTION WHEN ALIGNING POWER TURBINE AND GAS GENERATOR. ENSURE POWER TURBINE IS LOCATED FAR ENOUGH AFT TO PREVENT DAMAGE TO NO. 5 BEARING AND SEALS DURING ALIGNMENT. (4)

Using lift fixture, 1C6955, align power turbine with gas generator.

(5)

Apply petrolatum to No. 5 bearing rollers. Push rollers radially outward to provide as much clearance as possible for HPT rotor aft shaft. CAUTION

•

ENSURE POWER TURBINE AND GAS GENERATOR ARE PROPERLY ALIGNED BEFORE MOVING POWER TURBINE FORWARD. INACCURATE ALIGNMENT WILL RESULT IN DAMAGE TO NO. 5 BEARING.

•

USE EXTREME CAUTION WHEN MATING POWER TURBINE AND GAS GENERATOR, OR DAMAGE TO NO. 5 BEARING AND SEALS MAY OCCUR.

(6)

Using hoist and power turbine lift fixture, 1C6955, move power turbine forward.

(7)

Lightly coat bolt threads and contact faces of 136 bolts and self-locking nuts with thread lubricant.

(8)

Using 136 bolts, and self-locking nuts, secure TMF to CRF. Install brackets (figure 4) per matchmarks made at removal. Tighten bolts finger-tight.

(9)

Engage power turbine support posts, part of adapter set, 1C8302, into power turbine ground handling mount fixtures, 1C8321, per WP 303 00.

(10) Engage TRF support posts, part of adapter set, 1C8302, into TRF ground handling mount fixtures, 1C8321, per WP 303 00.




Figure 4. CRF Aft Flange to TMF Forward Flange 11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



(11) Final tighten 136 bolts as follows: (a) Tighten bolt in bolthole 1 to 162-178 lb in. (18.4-20.1 N⋅m) of torque. (b) Tighten bolt in bolthole 78 to 162-178 lb in. (18.4-20.1 N⋅m) of torque. (c) Tighten bolt in bolthole 34 to 162-178 lb in. (18.4-20.1 N⋅m) of torque. (d) Tighten bolt in bolthole 102 to 162-178 lb in. (18.4-20.1 N⋅m) of torque. (e) Continue tightening bolts, indexing one bolt clockwise, until all bolts are tightened to final torque. (12) Remove lift fixture, 1C6955, from power turbine. (13) Connect external tubing and piping (figure 1) between power turbine and gas generator as follows: (a) Connect balance piston air tube at power turbine-TMF flange per SWP 113 01. (b) Connect D-sump vent air tube at power turbine-TMF flange per SWP 113 01. (c) Connect D-sump pressurization tube at power turbine-TMF flange per SWP 113 01. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (d) Connect lube oil supply tube at power turbine-TMF flange per SWP 113 01. (e) Connect D-sump scavenge tube at power turbine-TMF flange per SWP 113 01.




(14) Connect external piping and tubing between gas generator and TMF as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Connect C-sump oil supply tube to TMF strut cap per SWP 113 01. (b) Connect C-sump scavenge tube to TMF strut cap per SWP 113 01. (c) Connect B- and C-sump drain tube to TMF strut cap per SWP 113 01. (d) Connect five cooling air tubes to TMF strut caps per SWP 113 01. (e) Connect two HP recoup air manifolds to TMF per SWP 113 01. (15) Disengage power turbine support posts, part of adapter set, 1C8302, from ground handling mount fixtures, 1C8321. (16) Remove ground handling mount fixtures, 1C8321 (figure 2), as follows: (a) Remove slave bolts, in boltholes 1 through 9, on horizontal split flange of power turbine stator case. (b) Lightly coat engine hardware threads and contact faces with thread lubricant. CAUTION DO NOT TURN BODY-BOUND BOLTS DURING INSTALLATION, OR DAMAGE TO POWER TURBINE STATOR CASING MAY OCCUR. (c) Reinstall and tighten bolts into power turbine stator case horizontal split flange per table 1. (d) Reinstall four bolts, washers, and nuts, on power turbine forward vertical flange, in boltholes immediately underneath both horizontal split-line flanges. Tighten bolts to 162-178 lb in. (18.4-20.1 N⋅m) of torque.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Horizontal Split-Line Bolt Placement

Bolt Size

Bolt Type

Bolthole Location

Final Torque

0.3125-24

Machine

1

276-304 lb in. (31.1-34.3 N⋅m)

0.3125-24

Body-Bound

2

162-178 lb in. (18.4-19.6 N⋅m)

0.3125-24

Machine

3 through 9

162-178 lb in. (18.4-19.6 N⋅m)

(17) Remove gas turbine from maintenance dolly, 1C9372, and adapter assembly 1C8302, per WP 303 00. (18) Install gas turbine into enclosure per WP 300 00.





TECHNICAL PROCEDURES TWO STAGE POWER TURBINE AND GAS GENERATOR JOINING KIT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Two Stage Power Turbine Joining Kit Installation........................................................... Two Stage Power Turbine Joining Kit Removal................................................................

8 4




Introduction.

This work package covers the installation and removal of the joining kit used when joining a gas generator and a two stage power turbine. For further information on two stage power turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown. 2.

3.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Five Element Lube and Scavenge Pump Replacement Gas Generator External Piping and Wiring Gas Generator Assembly Replacement Maintenance Dolly Usage Gas Generator/Gas Turbine Shipping Operation and Maintenance Manual Illustrated Parts Breakdown When converting to or from gas generator joining kit: Operation and Maintenance Manual, Volume II Gas Generator Joining Kit When converting to or from six stage power turbine: Operation and Maintenance Manual, Volume II Six Element Lube and Scavenge Pump Replacement Gas Turbine External Piping and Wiring Gas Generator and Power Turbine Separation and Joining Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 102 00 WP 113 00 WP 301 00 WP 303 00 WP 502 00 GEK 105052 GEK 105053 GEK 105054 SWP 216 02 GEK 105054 SWP 102 01 SWP 113 01 WP 216 00 GEK 105055



Heat Gun

Local Purchase




5.



Dry Ice Safety Cable Safety Wire Thread Lubricant

BB-C-104 736L680G01 R297P02 GE Spec A50TF201


IPB Figure No./Item

Preformed Packing

28-16




Two Stage Power Turbine Joining Kit Removal. a.


b.

Remove gas generator from enclosure per WP 301 00 or from shipping container per WP 502 00.

c.

Install gas generator into maintenance dolly per WP 303 00.

d.

Remove two stage power turbine joining kit hardware (figure 1) per table 1 and as follows: (1)

Remove 42 bolts (8) and self-locking nuts (7) that secure aft ring (9) to aft ring support (6). Remove aft ring. Table 1. Joining Kit Components Component

Figure 1 Call Out

Quantity

Brush Retainer

(1)

1

Machine Screw

(2)

8

Self-Locking Nut

(3)

8

Seal

(4)

1

Aft Outer Seal

(5)

1

Aft Ring Support

(6)

1

Self-Locking Nut

(7)

42

Bolt

(8)

42

Aft Ring

(9)

1

Bolt

(10)

32

Bolt

(11)

48

Heat Shield

(12)

1

Bolt*

(13)

22

HPT Adapter

(14)

1

Insulation Blanket

(15)

1

Cover

(16)

1

Preformed Packing

(17)

1

Insulation Blanket

(18)

1

* Install safety wire




Figure 1. Two Stage Power Turbine Joining Kit (Sheet 1 of 2) 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Two Stage Power Turbine Joining Kit (Sheet 2 of 2) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Remove aft ring support (6) from turbine mid frame (TMF) as follows: (a) Remove 32 bolts (10) that secure aft ring support (6) to TMF. WARNING

DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW-TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. (b) Using dry ice, chill aft ring support (6) for 20 minutes. WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING COLD PARTS. (c) Remove aft ring support (6) from TMF. NOTE Six stage power turbine configuration does not use HPT adapter; gas generator does use HPT adapter. CAUTION FOR OEM AND TWO STAGE HSPT GAS GENERATOR APPLICATIONS, FOUR TEE ASSEMBLIES (FIGURE 1, ITEM 19) MUST BE INSTALLED AT HUB LOCATIONS SHOWN ON FIGURE 1. TORQUE TEES TO 65 LB IN. (7.3 N⋅M). WHEN A TWO STAGE HSPT IS CONVERTED TO A SIX STAGE POWER TURBINE APPLICATION, THE TEE ASSEMBLIES MUST BE REMOVED TO PREVENT POWER TURBINE DAMAGE. (3)

If required, remove high pressure turbine (HPT) adapter (14) as follows: (a) Remove 48 bolts (11) that secure HPT adapter (14) to TMF. (b) Using heat gun, heat HPT adapter (14) flange. WARNING

WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (c) Remove HPT adapter (14) from TMF. NOTE Six stage power turbine TMF sump assembly configuration is different; gas generator TMF sump assembly configuration is same. 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II SWP 216 01 (4)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines If required, remove TMF sump assembly components as follows: (a) Remove safety wire that secures 22 bolts (13) to TMF sump housing. (b) Remove 22 bolts (13) that secure heat shield (12), cover (16), and insulation blankets (15 and 18) to TMF sump housing. (c) Remove heat shield (12), cover (16), and insulation blankets (15 and 18) from TMF sump housing. NOTE

Six stage power turbine TMF aft flange configuration uses different seal configuration; gas generator TMF aft flange configuration uses same seal configuration. (5)

If required, remove TMF aft flange components as follows: (a) Remove eight machine screws (2) and self-locking nuts (3) that secure brush retainer (1), seal (4), and aft outer seal (5) to TMF aft flange. (b) Remove brush retainer (1), seal (4), and aft outer seal (5) from TMF aft flange. NOTE

If retaining two stage power turbine configuration, following steps are not required. e.

If required, remove five element lube and scavenge pump per WP 102 00.

f.

If required, configure external piping, tubing, and wiring per SWP 113 01 for six element lube and scavenge pump installation.

g.

If required, install joining kit as follows:

h. 7.

(1)

Install six stage power turbine joining kit hardware per WP 216 00.

(2)

Install gas generator joining kit hardware per SWP 216 02.

If required, install six element lube and scavenge pump per SWP 102 01.

Two Stage Power Turbine Joining Kit Installation. a.

Comply with all instructions contained in WP 002 00, if not previously accomplished.

b.


c.





Remove joining kit hardware as follows: (1)

If required, remove six stage power turbine joining kit hardware.

(2)

If required, remove gas generator joining kit hardware per SWP 216 02.

e.

If required, configure external piping, tubing, and wiring per WP 113 00 for five element lube and scavenge pump.

f.

If required, install five element lube and scavenge pump per WP 102 00.

g.

Install gas generator joining kit hardware (figure 1) per table 1 and as follows: NOTE Six stage power turbine TMF aft flange configuration uses different seal configuration; gas generator TMF aft flange configuration uses same seal configuration. (1)

If required, configure TMF aft flange as follows: (a) Install seal (4) onto TMF aft flange. (b) Lightly coat threads and contact faces of eight machine screws (2) and self-locking nuts (3) with thread lubricant (c) Install brush retainer (1) onto TMF aft flange. (d) Using eight machine screws (2) and self-locking nuts (3), secure brush retainer (1), seal (4), and aft outer seal (5) to TMF aft flange. Tighten machine screws to 55-70 lb in. (6.2-7.9 N⋅m) of torque. NOTE

Six stage power turbine TMF sump assembly uses different configuration; gas generator TMF sump assembly configuration is same. (2)

If required, install TMF sump assembly components as follows: (a) Install preformed packing (17) into cover (16). (b) Install heat shield (12), cover (16), and insulation blankets (15 and 18) onto TMF sump housing. (c) Lightly coat threads of 22 bolts (13) with thread lubricant. (d) Using 22 bolts (13), secure heat shield (12), cover (16), and insulation blankets (15 and 18) to TMF sump housing. Tighten bolts to 33-37 lb in. (3.7-4.2 N⋅m) of torque and safety-wire.




(3) If required, install HPT adapter (14) onto TMF as follows: (a) Lightly coat threads of 48 bolts (11) with thread lubricant. (b) Using heat gun, heat HPT adapter (14) flange. WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (c) Install HPT adapter (14) onto TMF. (d) Using 48 bolts (11), secure HPT adapter (14) to TMF. Tighten bolts to 71.3-78.7 lb in. (8.06-8.89 N⋅m) of torque. (4)

Install aft ring support (6) onto TMF as follows: WARNING

DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW-TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. (a) Using dry ice, chill aft ring support (6) for 20 minutes. (b) Lightly coat threads of 32 bolts (10) with thread lubricant. WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING COLD PARTS. (c) Install aft ring support (6) onto TMF. (d) Using 32 bolts, secure aft ring support (6) to TMF. Tighten bolts to 55-70 lb in. (6.2-7.9 N⋅m) of torque. (5)

Install aft ring (9) onto aft ring support (6) as follows: (a) Lightly coat threads and contact faces of 42 bolts (8) and self-locking nuts (7) with thread lubricant. (b) Using 42 bolts (8) and self-locking nuts (7), install aft ring (9) onto aft ring support (6). Tighten nuts to 33.3-36.7 lb in. (3.76-4.15 N⋅m) of torque.

h.

Install gas generator into enclosure per WP 301 00 or packager’s manual.





TECHNICAL PROCEDURES GAS GENERATOR JOINING KIT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK AND GV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Gas Generator Joining Kit Installation. ............................................................................ Gas Generator Joining Kit Removal. .................................................................................

9 4




Introduction.

This work package covers the installation and removal of the joining kit used when joining a gas generator and packager supplied power turbine. When converting to or from two stage power turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown. 2.

3.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Five Element Lube and Scavenge Pump Replacement Gas Generator External Piping and Wiring Gas Generator Assembly Replacement Maintenance Dolly Usage Gas Generator/Gas Turbine Shipping Illustrated Parts Breakdown When converting to or from two stage power turbine: Operation and Maintenance Manual, Volume II Two Stage Power Turbine and Gas Generator Joining Kit Operation and Maintenance Manual Illustrated Parts Breakdown When converting to or from six stage power turbine: Operation and Maintenance Manual, Volume II Six Element Lube and Scavenge Pump Replacement Gas Turbine External Piping and Wiring Six Stage Power Turbine and Gas Generator Joining Kit Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 102 00 WP 113 00 WP 301 00 WP 303 00 WP 502 00 GEK 105055 GEK 105054 SWP 216 01 GEK 105052 GEK 105053 GEK 105054 SWP 102 01 SWP 113 01 WP 216 00 GEK 105055



Heat Gun

Local Purchase




5.



Dry Ice Safety Cable Safety Wire Thread Lubricant

BB-C-104 736L680G01 R297P02 GE Spec A50TF201


IPB Figure No./Item

Preformed Packing

28-16




Gas Generator Joining Kit Removal. a.


b.


c.


d.

Remove gas generator joining kit hardware (figure 1) per table 1 and as follows: (1)

Remove 42 bolts (8) and self-locking nuts (7) that secure aft cover (14) to aft cover support (6). Remove aft cover. Table 1. Joining Kit Components

Component

Figure 1 Call Out

Quantity

Brush Retainer

(1)

1

Machine Screw

(2)

8

Self-Locking Nut

(3)

8

Seal

(4)

1

Aft Outer Seal

(5)

1

Aft Cover Support

(6)

1

Self-Locking Nut

(7)

42

Bolt

(8)

42

Bolt

(9)

32

Bolt

(10)

48

Heat Shield

(11)

1

Bolt*

(12)

22

HPT Adapter

(13)

1

Aft Cover

(14)

1

Insulation Blanket

(15)

1

Cover

(16)

1

Preformed Packing

(17)

1

Insulation Blanket

(18)

1

* Install safety wire




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



Figure 1. Gas Generator Joining Kit (Sheet 2 of 2) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Remove aft cover support (6) from turbine mid frame (TMF) as follows: (a) Remove 32 bolts (9) that secure aft cover support (6) to TMF. WARNING

DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW-TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. (b) Using dry ice, chill aft cover support (6) for 20 minutes. WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING COLD PARTS. (c) Remove aft cover support (6) from TMF. NOTE Six stage power turbine configuration does not use HPT adapter; two stage power turbine does use HPT adapter. CAUTION FOR OEM AND TWO STAGE HSPT GAS GENERATOR APPLICATIONS, FOUR TEE ASSEMBLIES (FIGURE 1, ITEM 19) MUST BE INSTALLED AT HUB LOCATIONS SHOWN ON FIGURE 1. TORQUE TEES TO 65 LB IN. (7.3 N⋅M). WHEN A TWO STAGE HSPT IS CONVERTED TO A SIX STAGE POWER TURBINE APPLICATION, THE TEE ASSEMBLIES MUST BE REMOVED TO PREVENT POWER TURBINE DAMAGE. (3)

If required, remove high pressure turbine (HPT) adapter (13) as follows: (a) Remove 48 bolts (10) that secure HPT adapter (13) to TMF. (b) Using heat gun, heat HPT adapter (13) flange. WARNING

WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (c) Remove HPT adapter (13) from TMF.




Six stage power turbine TMF sump assembly configuration is different; two stage power turbine TMF sump assembly configuration is same. (4)

If required, remove TMF sump assembly components as follows: (a) Remove safety wire that secures 22 bolts (12) to TMF sump housing. (b) Remove 22 bolts (12) that secure heat shield (11), cover (16), and insulation blankets (15 and 18) to TMF sump housing. (c) Remove heat shield (11), cover (16), and insulation blankets (15 and 18) from TMF sump housing. NOTE

Six stage power turbine TMF aft flange configuration uses different seal configuration; two stage power turbine TMF aft flange configuration uses same seal configuration. (5)

If required, remove TMF aft flange components as follows: (a) Remove eight machine screws (2) and self-locking nuts (3) that secure brush retainer (1), seal (4), and aft outer seal (5) to TMF aft flange. (b) Remove brush retainer (1), seal (4), and aft outer seal (5) from TMF aft flange. NOTE

If retaining packager supplied power turbine configuration, following steps are not required. e.

If required, remove five element lube and scavenge pump per WP 102 00.

f.

If required, configure external piping, tubing, and wiring per SWP 113 01 for six element lube and scavenge pump installation.

g.

If required, install joining kit as follows:

h.

(1)

Install six stage power turbine joining kit hardware per WP 216 00.

(2)

Install two stage power turbine joining kit hardware per SWP 216 01.

If required, install six element lube and scavenge pump per SWP 102 01.




Gas Generator Joining Kit Installation. a.

Comply with all instructions contained in WP 002 00, if not previously accomplished.

b.


c.


d.

Remove joining kit hardware as follows: (1)

If required, remove six stage power turbine joining kit hardware per SWP 216 01.

(2)

If required, remove two stage power turbine joining kit hardware per SWP 216 01.

e.

If required, configure external piping, tubing, and wiring per WP 113 00 for five element lube and scavenge pump.

f.

If required, install five element lube and scavenge pump per WP 102 00.

g.

Install gas generator joining kit hardware (figure 1) per table 1 and as follows: NOTE Six stage power turbine TMF aft flange configuration uses different seal configuration; two stage power turbine TMF aft flange configuration uses same seal configuration. (1)

If required, configure TMF aft flange as follows: (a) Install seal (4) onto TMF aft flange. (b) Lightly coat threads and contact faces of eight machine screws (2) and self-locking nuts (3) with thread lubricant. (c) Install brush retainer (1) onto TMF aft flange. (d) Using eight machine screws (2) and self-locking nuts (3), secure brush retainer (1), seal (4), and aft outer seal (5) to TMF aft flange. Tighten machine screws to 55-70 lb in. (6.2-7.9 N⋅m) of torque.




Six stage power turbine TMF sump assembly uses different configuration; two stage power turbine TMF sump assembly configuration is same. (2)

If required, install TMF sump assembly components as follows: (a) Install preformed packing (17) into cover (16). (b) Install heat shield (11), cover (16), and insulation blankets (15 and 18) onto TMF sump housing. (c) Lightly coat threads of 22 bolts (12) with thread lubricant. (d) Using 22 bolts (12), secure heat shield (11), cover (16), and insulation blankets (15 and 18) to TMF sump housing. Tighten bolts to 33-37 lb in. (3.7-4.2 N⋅m) of torque and safety-wire.

(3)

If required, install HPT adapter (13) onto TMF as follows: (a) Lightly coat threads of 48 bolts (10) with thread lubricant. (b) Using heat gun, heat HPT adapter (13) flange. WARNING

WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (c) Install HPT adapter (13) onto TMF. (d) Using 48 bolts (10), secure HPT adapter (13) to TMF. Tighten bolts to 71.3-78.7 lb in. (8.06-8.89 N⋅m) of torque. (4)

Install aft cover support (6) onto TMF as follows: WARNING

DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW-TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. (a) Using dry ice, chill aft cover support (6) for 20 minutes. (b) Lightly coat threads of 32 bolts (9) with thread lubricant.




WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING COLD PARTS. (c) Install aft cover support (6) onto TMF. (d) Using 32 bolts, secure aft cover support (6) to TMF. Tighten bolts to 55-70 lb in. (6.2-7.9 N⋅m) of torque. (5)

Install aft cover (14) onto aft cover support (6) as follows: (a) Lightly coat threads and contact faces of 42 bolts (8) and self-locking nuts (7) with thread lubricant. (b) Using 42 bolts (8) and self-locking nuts (7), install aft cover (14) onto aft cover support (6). Tighten nuts to 33-37 lb in. (3.7-4.2 N⋅m) of torque.

h.

Install gas generator into enclosure per WP 301 00 or packager’s manual.




WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR MISCELLANEOUS SUMP COMPONENTS REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 22 ................. 0


Page

A-Sump Components Replacement. ................................................................................... 3 B-Sump Components Replacement. ................................................................................... 12 C-Sump Components Replacement. ................................................................................... 15


GEK 105054 Volume II WP 217 00 1.


Introduction. This work package contains instructions for field replacement of components of LM2500+ Models GK, GV, and PV gas generator A-, B-, and C-sump areas.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume I General Maintenance Practices Operation and Maintenance Manual, Volume II General Maintenance Practices Turbine Mid Frame Replacement High Pressure Turbine Rotor Replacement High Pressure Turbine Stage 1 Nozzle Assembly Replacement Compressor Front Frame Replacement Gas Generator and Power Turbine Separation and Joining Gas Generator Assembly Replacement

GEK 105054 Chapter 10 GEK 105054 WP 002 00 WP 200 00 WP 201 00

WP 216 00 WP 301 00


Part No.

Jackscrews, Flange Disassemble Tool Set Pins, Guide-Brg and Seal Installation Puller, No. 5R Bearing Inner Race Clamping Set, O-Ring Installation Pusher, No. 5R Bearing Inner Race Wrench, No. 3R Bearing Race Spanner Nut Pusher, No. 3R Bearing Inner Race Puller, No. 3R Bearing Inner Race Multiplier, Torque Pump, Enerpac Hydraulic

1C6804G04 1C6898G01 1C6899G01 1C6905G01 2C6196G01 2C6001G01 2C6002G01 2C6003G01 Sweeny Model 8100 Local Purchase



Dry Ice Isopropyl Alcohol Lubricating Oil Marking Pen

Fed Spec BB-C-104 Fed Spec TT-I-735 MIL-PRF-23699F Sharpie T.E.C or Action Marker Local Purchase GE Spec A50TF201

Shim Stock Thread Lubricant 5.

SWP 201 02 WP 210 00





A-Sump Components Replacement. a.

Comply with all instructions contained in WP 002 00. NOTE No. 3R bearing and inner race are matched assemblies and share same serial number. Replacement of compressor front frame shall include replacement of No. 3R bearing inner race.

b.

Replace No. 3R bearing inner race as follows: (1)

Remove compressor front frame (CFF) per WP 210 00.

(2)

Remove No. 3R bearing spanner nut (4, figure 1) as follows: (a) Using pointed tool and needle nose pliers, remove retaining ring (1) from blisk forward shaft (6). (b) Using pointed tool and needle nose pliers, remove spacer ring (2) from blisk forward shaft (6). (c) Using pointed tool and needle nose pliers, remove keyed retaining ring (3) from No. 3R bearing spanner nut (4). NOTE

Ensure No. 3R bearing race spanner nut wrench, 2C6001, part holder seats in blisk forward shaft spline sufficiently so slot in No. 3R bearing race spanner nut wrench, 2C6001, spanner plate drive engages mating portion of part holder. (d) Slide No. 3R bearing race spanner nut wrench, 2C6001, part holder (1, figure 2) into blisk forward shaft (2). (e) Slide No. 3R bearing race spanner nut wrench, 2C6001, spanner plate drive (5) over part holder (1) so it engages No. 3R bearing spanner nut (4). (f) Install Sweeny torque multiplier, Model 8100 (6), onto No. 3R bearing race spanner nut wrench, 2C6001 with antitorque lugs facing aft.




Figure 1. No. 3R Bearing Inner Race

Figure 2. No. 3R Bearing Race Spanner Wrench, 2C6001 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



(g) Install spanner plate (7) and antitorque pipe onto No. 3R bearing race spanner nut wrench, 2C6001, part holder (1). Secure spanner plate using hand knob (8). (h) Using Sweeny torque multiplier, Model 8100 (6), turn No. 3R bearing race spanner nut wrench, 2C6001, spanner plate drive (5) to remove No. 3R bearing spanner nut (4). (i) Remove Sweeny torque multiplier, Model 8100 (6), and No. 3R bearing race spanner nut wrench, 2C6001, from blisk forward shaft (2). (3)

Remove No. 3R bearing inner race (3, figure 3) as follows: (a) Place No. 3R bearing inner race puller, 2C6003, plate (6) against blisk forward shaft (5). (b) Place No. 3R bearing inner race puller, 2C6003, puller halves (4) over No. 3R bearing inner race (3) so lip catches aft edge of No. 3R bearing inner race. (c) Slide No. 3R bearing inner race puller, 2C6003, large ring (2) over puller halves (4). (d) Attach Enerpac hydraulic pump to No. 3R bearing inner race puller, 2C6003, hydraulic inlet port (1). WARNING

•

TO AVOID POSSIBLE INJURY, DO NOT STAND IN DIRECT LINE WITH PUSHER/PULLER WHEN APPLYING HYDRAULIC PRESSURE.

•


(e) Using Enerpac hydraulic pump and No. 3R bearing inner race puller, 2C6003, remove No. 3R bearing inner race. Handle No. 3R bearing inner race per GEK 105054, Chapter 10. (4)

Install No. 3R bearing inner race as follows: (a) Heat No. 3R bearing inner race (2, figure 4) in 350°F (176°C) oven for approximately 20 minutes.




Figure 3. No. 3R Bearing Inner Race Puller, 2C6003

Figure 4. No. 3R Bearing Inner Race Pusher, 2C6002 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (b) Slide No. 3R bearing inner race (2) onto blisk forward shaft (3) as far as possible using hand pressure. (c) Thread No. 3R bearing inner race pusher, 2C6002 (1), onto blisk forward shaft (3). (d) Continue to thread No. 3R bearing inner race pusher, 2C6002 (1), onto blisk forward shaft (3) until No. 3R bearing inner race (2) is fully seated onto blisk forward shaft. (5)

Install No. 3R bearing spanner nut (4, figure 1) as follows: WARNING

ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Using isopropyl alcohol, clean blisk forward shaft (6) threads and No. 3R bearing spanner nut (4) threads and contact face. (b) Using thread lubricant, coat blisk forward shaft (6) threads and No. 3R bearing spanner nut (4) threads and mate face. (c) Thread No. 3R bearing spanner nut (4) onto blisk forward shaft (6) as far as possible by hand. NOTE Ensure No. 3R bearing race spanner nut wrench, 2C6001, part holder seats in blisk spline sufficiently so slot in No. 3R bearing race spanner nut wrench, 2C6001, spanner plate, engages mating portion of part holder. (d) Slide No. 3R bearing race spanner nut wrench, 2C6001, part holder (1, figure 2) into blisk forward shaft (2). (e) Slide No. 3R bearing race spanner nut wrench, 2C6001, spanner plate drive (5) over part holder (1) so it engages No. 3R bearing spanner nut (4). (f) Install Sweeny torque multiplier, Model 8100 (6), onto No. 3R bearing race spanner nut wrench, 2C6001 with antitorque lugs facing aft. (g) Install spanner plate (7) and antitorque pipe onto No. 3R bearing race spanner nut wrench, 2C6001, part holder (1). Secure spanner plate using hand knob (8). 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



EXERCISE EXTREME CARE WHEN USING TORQUE MULTIPLIER. IMPROPER USE CAN CAUSE EXTENSIVE DAMAGE TO ENGINE PARTS. DOUBLE CHECK ALL TORQUE CALCULATIONS BEFORE APPLYING TORQUE. (h) Using Sweeny torque multiplier, Model 8100 (6), turn No. 3R bearing race spanner nut wrench, 2C6001, spanner plate drive (5) to install No. 3R bearing spanner nut (4). Tighten spanner nut to 950-1050 lb ft (1289-1423 N⋅m) of torque. (i) Using Sweeny torque multiplier, Model 8100 (6), turn No. 3R bearing race spanner nut wrench, 2C6001, spanner plate drive (5) to break torque on No. 3R bearing spanner nut (4). (j)

Using Sweeny torque multiplier, Model 8100 (6), turn No. 3R bearing race spanner nut wrench, 2C6001, spanner plate drive (5) to retighten No. 3R bearing spanner nut (4). Tighten No. 3R bearing spanner nut to 450 lb ft (610 N⋅m) of torque.

(k) Visually inspect alignment of No. 3R bearing spanner nut (4, figure 1) and blisk forward shaft (6). Slots shall be aligned to accept keyed retaining ring (3). CAUTION DO NOT EXCEED 500 LB FT (678 NÞM) OF TORQUE WHEN APPLYING FINAL TORQUE. FAILURE TO COMPLY COULD RESULT IN DAMAGE TO ENGINE. (l) If required, align slots using Sweeny torque multiplier, Model 8100 (6, figure 2), to turn No. 3R bearing race spanner nut wrench, 2C6001, spanner plate drive (5). (m) Using 0.001 inch (0.2 mm) shim stock, check for No. 3R bearing inner race (3) seating. Shim shall not be accepted for full 360 degree circumference of No. 3R bearing inner race. (n) Remove Sweeny torque multiplier, Model 8100 (6), and No. 3R bearing race spanner nut wrench, 2C6001, from blisk forward shaft (2). (o) Install keyed retaining ring (3, figure 1), spacer ring (2), and retaining ring (1) into No. 3R bearing spanner nut (4).



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (5A) Replace No. 3 bearing stationary oil seal (3, figure 4A) as follows:

(a) Remove retaining ring (5) and A-sump air seal (4) using A-sump air seal puller, 1C8303G01, as follows: 1

Place CFF face down on flat surface.

2

Apply a load test of 500 lbs (227 kg) at both chain shackle locations of puller. No indications interpreted as cracks or permanent deformation allowed. NOTE

Make sure plunger of hydraulic cylinder is threaded flush with surface of puller plate (bottom plate). 3

Move puller into position over CFF and align with air seal (4).

4

Lower puller onto CFF, making sure that lip of puller plate engages at mounting flange of air seal.

5

Remove air seal (4) and retaining ring (5). CAUTION

JACKSCREWS SHALL BE USED TO PREVENT BINDING AND DAMAGE TO GAS GENERATOR PARTS. (b) Remove safety wire and 17 bolts (6) that secure stationary oil seal (3) to CFF. Remove seal. Use jackscrews, from tool set, 1C6804, as necessary to prevent damage to parts. (c) Remove and discard preformed packing (2) from outside diameter (OD) of forward flange of stationary oil seal (3) and preformed packing (7) from oil drain counterbore on forward face of forward flange. See figure 4A. (d) Lubricate new preformed packing (2) with oil, C02-023, and install in groove on forward OD of stationary oil seal. Use clamp set, 1C6905, to compress preformed packing in groove. (e) Chill stationary oil seal, with preformed packing and clamp installed, in dry ice for approximately 20 minutes. (f) Install guide pins, 1C6898P02, in stationary oil seal mounting flange on aft side of frame in holes 6 and 17, counting clockwise with No. 1 hole at 6:00 o’clock position. (g) Remove stationary oil seal from dry ice and remove preformed packing clamp. Lubricate preformed packing (7) with oil, C02-023, and install on stationary oil seal in oil drain counterbore on forward face of forward flange. Make sure preformed packing stays in place.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (h) Align boltholes of stationary oil seal (3) to seal mount on rear of CFF. Ensure oil drain hole is at 6:00 o’clock position. (i)

Secure stationary oil seal to CFF with 17 bolts (6). Allow seal to reach room temperature.

(j)

Remove guide pins and tighten bolts to 33-37 lb in. (3.7-4.2 N⋅m) of torque.

(k) Safety-wire bolts (6). Length of loop of safety wire shall not extend beyond OD flange of seal. (l)

Install A-sump air seal (4) and retaining ring (5) as follows: WARNING

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

(6)

1

Place A-sump air seal (4) in freezer for 15-20 minutes.

2

Remove air seal from freezer and install to CFF by aligning TOP mark on air seal with 12:00 o’clock position on CFF. Guide pins, 1C6898G02/P02, may be used to align air seal.

3

Install retaining ring (5) in groove of CFF just aft of air seal seating flange, to secure air seal to CFF.

Install CFF per WP 210 00.




Figure 4A. Removal/Installation of A-Sump Stationary Seals 11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 217 00 7.


B-Sump Components Replacement. a.

Comply with all instructions contained in WP 002 00. NOTE B-sump component replacement is limited to aft stationary air seal.

b.

Replace aft stationary air seal as follows: (1)

Separate gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.

(2)


(3)

Remove high pressure turbine (HPT) rotor (2, figure 5) per WP 201 00.

(4)

Remove HPT stage 1 nozzle (1), HPT stage 1 nozzle support (4), baffle liner (6) and compressor rear frame (CRF) seal support (3) per SWP 201 02.

(5)

Remove aft stationary air seal (5) as follows: (a) Using marking pen, matchmark aft stationary air seal (5) to CRF. CAUTION

USE EXTREME CARE WHEN REMOVING AFT STATIONARY AIR SEAL TO NOT LOOSEN FORWARD STATIONARY AIR SEAL RABBET FIT TO VENT AIR STATIONARY SEAL. (b) Remove 40 bolts (7) that secure aft stationary air seal (5) to forward stationary air seal (8). (c) Using jackscrews, 1C6804, break aft stationary air seal (5) loose from forward stationary air seal (8). (d) Remove aft stationary air seal (5) from CRF. (e) Temporarily reinstall bolts (7) finger-tight to secure forward air seal (8) to vent air stationary seal (9). (6)

Install aft stationary air seal (5) as follows: (a) Remove bolts (7) that temporarily secure forward stationary air seal (8) to vent air stationary seal (9). (b) Lubricate 40 bolts (7) with thread lubricant.




Figure 5. Aft Stationary Air Seal 13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Prior to seating, visually inspect aft stationary air seal for jackscrew hole alignment. Jackscrew hole in aft stationary air seal shall be one bolthole counterclockwise from jackscrew hole in outer stationary air seal, when aft stationary air seal is properly installed. (c) Position aft stationary air seal (5), aligning matchmarks made when aft stationary air seal was removed. If aft stationary air seal is not matchmarked, align TOP mark on aft stationary air seal to top vertical centerline of CRF. WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (d) Using heat gun, heat aft stationary air seal (5) forward flange to aid in seating. CAUTION USE CARE WHEN INSTALLING BOLTS. EXCESSIVE END PRESSURE APPLIED TO BOLTS CAN PUSH NUTS FROM GANG CHANNELS. (e) Use 40 lubricated bolts (7) to secure aft stationary air seal (5). Tighten bolts finger-tight. (f) After aft stationary air seal (5) reaches room temperature, tighten bolts (7) to 55-70 lb in. (6.3-7.9 N·m) of torque. (7)

Install HPT stage 1 nozzle assembly (1), HPT stage 1 nozzle support (4), baffle liner (6), and CRF seal support (3) per SWP 201 02.

(8)

Install HPT rotor per WP 201 00.

(9)


(10) Join gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.




C-Sump Components Replacement. a.

Comply with all instructions contained in WP 002 00. NOTE No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of TMF shall include replacement of No. 5R bearing inner race.

b.

Remove the seals and the No. 5 bearing from the C-sump (figure 6) as follows: (1)

Remove bolts securing air cooling and vent seal (1).

(2)

Using jackscrews, 1C6804, remove air cooling and vent seal (1) from frame.

(3)

Remove bolts securing forward heat shield (2). Remove forward heat shield (2).

(4)

Using jackscrews, 1C6804, remove No. 5 bearing air and oil seal (4). Remove and discard O-ring (5).

(5)

Remove 12 bolts securing No. 5 bearing retainer (6) and remove retainer. NOTE

No. 5 bearing and inner race are matched assemblies and share same serial number. They must be maintained as a set.

c.

(6)

Remove No. 5 bearing (7) by pulling forward with hand pressure. Place bearing in plastic bag and identify. Handle bearing per Volume I, Chapter 5.

(7)

Remove forward sump insulation blanket (3).

Install the No. 5 bearing (7) and the C-sump forward seals as follows: NOTE No. 5 bearing and inner race are matched assemblies and share same serial number. They must be maintained as a set. (1)

Install alignment pins, 1C6898, in No. 5 bearing mounting flange.




Figure 6. Turbine Mid Frame Assembly




WARNING LUBRICATING OIL, MIL-PRF-23699F (C/I): COMBUSTIBLE. DO NOT INHALE, INGEST, OR LET THIS MATERIAL TOUCH YOU. IRRITANT. PERSONAL PROTECTIVE EQUIPMENT REQUIRED. USE MECHANICAL EXHAUST VENTILATION - IF NOT AVAILABLE, USE AN APPROVED RESPIRATOR. CAUTION FAILURE TO COMPLY WITH INSTRUCTIONS GIVEN IN VOLUME I, CHAPTER 5 CAN RESULT IN BEARING FAILURE. (2)

Install No. 5 bearing (7) into bearing housing from forward side, with lugs on bearing facing forward.

(3)

Install bearing retainer (6) onto bearing with slots in retainer engaging lugs on bearing and align boltholes.

(4)

Use 12 lubricated bolts to secure bearing retainer (6). Tighten bolts to 60-70 lb in. (6.8-7.9 N·m) of torque and safety wire.

(5)

Install forward sump insulation blanket (3) around sump.

(6)

Install No. 5 bearing forward air and oil seal (4) as follows: (a) Lubricate new O-ring (5) with lubricating oil. (b) Install new O-ring (5) onto the No. 5 air and oil seal (4). (c) Using clamping set, 1C6905, compress seal. WARNING

DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW-TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. (d) Using dry ice, chill air and oil seal (4) with clamp set installed for approximately 20 minutes. (e) Install alignment pins in air and oil seal mounting flange. (f) Remove air and oil seal from dry ice and remove clamp set from O-ring.




DO NOT APPLY EXCESSIVE END PRESSURE TO BOLTS/SCREWS AS NUTS MAY BE PUSHED FROM GANG CHANNELS. (g) Install air and oil seal (4) into TMF housing, ensure the oil drain hole is at approximately 7:00 o’clock position (forward looking aft). (h) Using four equally-spaced bolts and four slave washers, seat seal. When seal is seated and temperature has stabilized, remove bolts and washers. NOTE Forward insulation blanket shall be hand formed (front edge bent radially inward) if required to eliminate interference with heat shield. Hand forming is not required for P/N L44597. (i) Install forward heat shield over air and oil seal (4). Align boltholes and seal drain cutout, and secure with 22 bolts. Remove alignment pins as last two bolts are installed. (j)

Apply thread lubricant to threads of bolts.Tighten bolts to 33-37 lb in. (3.7-4.2 N·m) of torque. CAUTION

DO NOT APPLY EXCESSIVE END PRESSURE TO BOLTS/SCREWS AS NUTS MAY BE PUSHED FROM GANG CHANNELS. (7)

Install alignment pins, 1C6898, in air cooling and vent seal mounting flange. WARNING

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY. (8)

Heat forward air cooling and vent seal (1) in an oven at approximately 200°F (93°C) for 20 minutes.

(9)

Remove seal from oven and install in frame. Ensure the air tubes are aligned with holes in frame.

(10) Use 40 lubricated bolts to secure seal. Remove alignment pins as last 2 bolts are installed. Torque to 55-70 lb in. (6.2-7.9 N·m). d.

Replace No. 5R bearing inner race (2, figure 7) as follows: (1)





Figure 7. No. 5R Bearing Inner Race (2)

Remove TMF per WP 200 00.

(3)

Remove No. 5R bearing spanner nut (1) per WP 201 00.

(4)

Remove No. 5R bearing inner race as follows: (a) Install puller, 1C6899, halves (6, figure 8) over No. 5R bearing inner race (5). (b) Engage three forward tangs of puller, 1C6899, halves (6) to forward edge of No. 5R bearing inner race (5). (c) Install large ring (4) to hold puller, 1C6899, halves (6) in place. (d) Insert hydraulic puller sleeve (3) and plate (2) into puller, 1C6899, halves (6). Ensure hydraulic puller sleeve seats into HPT rotor aft shaft (7). (e) Attach Enerpac hydraulic pump to No. 5R bearing inner race puller, 1C6899, hydraulic inlet port (1).




Figure 8. No. 5R Bearing Inner Race Puller, 1C6899

WARNING

•


•


(f) Apply hydraulic pressure to pull No. 5R bearing inner race (5) from HPT rotor aft shaft (7). (g) Remove puller, 1C6899, and No. 5R bearing inner race (5) from HPT rotor aft shaft (7).




Figure 9. No. 5R bearing Inner Race Pusher, 2C6196


GEK 105054 Volume II WP 217 00 (5)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Install No. 5R bearing inner race (2, figure 9) onto HPT aft shaft (1) as follows: (a) Heat No. 5R bearing inner race (2) in oven at approximately 350°F (176°C) for 20 minutes. WARNING

WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (b) Remove No. 5R bearing inner race (2) from oven and install onto HPT rotor aft shaft (1). (c) Thread No. 5R bearing inner race pusher, 2C6196 (3), onto HPT rotor aft shaft (1). (d) Continue to thread No. 5R bearing inner race pusher, 2C6196 (3), onto HPT rotor aft shaft (1) until No. 5R bearing inner race (2) is fully seated onto HPT rotor aft shaft. (e) Allow No. 5R bearing inner race (2) to cool to ambient temperature. (f) Remove pusher, 2C6196 (3), from No. 5R bearing inner race (2) and HPT rotor aft shaft (1). (6)

Install No. 5R bearing spanner nut (1, figure 7) per WP 201 00.

(7)


(8)

Join gas generator and power turbine per WP 216 00, WP 301 00, or packager’s manual, as applicable.





TECHNICAL PROCEDURES GAS TURBINE MISCELLANEOUS SUMP COMPONENTS REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.


Page

A-Sump Components Replacement. ................................................................................... 3 B-Sump Components Replacement. ................................................................................... 3 C-Sump Components Replacement. ................................................................................... 3 D-Sump Components Replacement. ................................................................................... 13 Power Turbine Stage 1 Nozzle Components Replacement. .............................................. 13




Introduction. This work package contains instructions for replacement of major components of LM2500+ Model PK gas turbine A-, B-, C-, and D-sumps. Also included is the power turbine stage 1 nozzle components replacement.

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume I General Maintenance Practices Operation and Maintenance Manual, Volume II General Maintenance Practices Turbine Mid Frame Replacement High Pressure Turbine Rotor Replacement High Pressure Turbine Stage 1 Nozzle Assembly Replacement Gas Generator and Power Turbine Separation and Joining Gas Generator Miscellaneous Sump Components Replacement Gas Generator Assembly Replacement Power Turbine Assembly Replacement

GEK 105054 Chapter 10 GEK 105054 WP 002 00 WP 200 00 WP 201 00 SWP 201 02 WP 216 00 WP 217 00 WP 301 00 WP 302 00


Part No.

Puller, No. 6R Bearing Inner Race and Rotating Oil Seal Pusher, No. 6R Bearing and Seal Race Set, Jackscrew Wrench, No. 6R bearing spanner nut Pins, Alignment Clamping Set, O-Ring Installation Multiplier, Torque Pump, Enerpac Hydraulic

1C5691G04 1C5702G01 1C6804 1C6856G01 1C6898 1C6905G01 Sweeny, Model 8100 Local Purchase



Dry Ice Isopropyl Alcohol Lubricating Oil Thread Lubricant

Fed Spec BB-C-104 Fed Spec TT-I-735 MIL-PRF-23699F GE Spec A50TF201





A-Sump Components Replacement. a.

7.

B-Sump Components Replacement. a.

8.

Replace A-sump components per WP 217 00.

Replace B-sump components per WP 217 00.

C-Sump Components Replacement. a.

Comply with all instructions contained in WP 002 00. NOTE No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of turbine mid frame shall include replacement of No. 5R bearing inner race.

b.

Remove the seals and the No. 5 bearing from the C-sump (figure 1) as follows: (1)

Remove bolts securing air cooling and vent seal (1).

(2)

Using jackscrews, 1C6804, remove air cooling and vent seal (1) from frame.

(3)

Remove bolts securing forward heat shield (2). Remove forward heat shield (2).

(4)

Using jackscrews, 1C6804, remove No. 5 bearing air and oil seal (4). Remove and discard O-ring (5).

(5)

Remove 12 bolts securing No. 5 bearing retainer (6) and remove retainer. NOTE

No. 5 bearing and inner race are matched assemblies and share same serial number. They must be maintained as a set.

c.

(6)

Remove No. 5 bearing (7) by pulling forward with hand pressure. Place bearing in plastic bag and identify. Handle bearing per Volume I, Chapter 5.

(7)

Remove forward sump insulation blanket (3).

Install the No. 5 bearing (7) and the C-sump forward seals as follows: NOTE No. 5 bearing and inner race are matched assemblies and share same serial number. They must be maintained as a set. (1)

Install alignment pins, 1C6898, in No. 5 bearing mounting flange. 3




Figure 1. Turbine Mid Frame Assembly




WARNING LUBRICATING OIL, MIL-PRF-23699F (C/I): COMBUSTIBLE. DO NOT INHALE, INGEST, OR LET THIS MATERIAL TOUCH YOU. IRRITANT. PERSONAL PROTECTIVE EQUIPMENT REQUIRED. USE MECHANICAL EXHAUST VENTILATION - IF NOT AVAILABLE, USE AN APPROVED RESPIRATOR. CAUTION FAILURE TO COMPLY WITH INSTRUCTIONS GIVEN IN VOLUME I, CHAPTER 5 CAN RESULT IN BEARING FAILURE. (2)

Install No. 5 bearing (7) into bearing housing from forward side, with lugs on bearing facing forward.

(3)

Install bearing retainer (6) onto bearing with slots in retainer engaging lugs on bearing and align boltholes.

(4)

Use 12 lubricated bolts to secure bearing retainer (6). Tighten bolts to 60-70 lb in. (6.8-7.9 N⋅m) of torque and safety wire.

(5)

Install forward sump insulation blanket (3) around sump.

(6)

Install No. 5 bearing forward air and oil seal (4) as follows: (a) Lubricate new O-ring (5) with lubricating oil. (b) Install new O-ring (5) onto the No. 5 air and oil seal (4). (c) Using clamping set, 1C6905, compress seal. WARNING

DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW-TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. (d) Using dry ice, chill air and oil seal (4) with clamp set installed for approximately 20 minutes. (e) Install alignment pins in air and oil seal mounting flange. (f) Remove air and oil seal from dry ice and remove clamp set from O-ring.




DO NOT APPLY EXCESSIVE END PRESSURE TO BOLTS/SCREWS AS NUTS MAY BE PUSHED FROM GANG CHANNELS. (g) Install air and oil seal (4) into TMF housing, ensure the oil drain hole is at approximately 7:00 o’clock position (forward looking aft). (h) Using four equally-spaced bolts and four slave washers, seat seal. When seal is seated and temperature has stabilized, remove bolts and washers. NOTE Forward insulation blanket shall be hand formed (front edge bent radially inward) if required to eliminate interference with heat shield. Hand forming is not required for P/N L44597. (i) Install forward heat shield over air and oil seal (4). Align boltholes and seal drain cutout, and secure with 22 bolts. Remove alignment pins as last two bolts are installed. (j)

Apply thread lubricant to threads of bolts.Tighten bolts to 33-37 lb in. (3.7-4.2 N⋅m) of torque. CAUTION

DO NOT APPLY EXCESSIVE END PRESSURE TO BOLTS/SCREWS AS NUTS MAY BE PUSHED FROM GANG CHANNELS. (7)

Install alignment pins, 1C6898, in air cooling and vent seal mounting flange. WARNING

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY. (8)

Heat forward air cooling and vent seal (1) in an oven at approximately 200°F (93°C) for 20 minutes.

(9)

Remove seal from oven and install in frame. Ensure the air tubes are aligned with holes in frame.

(10) Use 40 lubricated bolts to secure seal. Remove alignment pins as last 2 bolts are installed. Torque to 55-70 lb in. (6.2-7.9 N⋅m). d.

Replace No. 5R bearing components as follows: (1)





Replace turbine mid frame (TMF) and No. 5R bearing inner race per WP 217 00. NOTE

Replacement of No. 6R bearing shall be accomplished at depot level. Field level maintenance is limited to turbine mid frame, No. 6R bearing inner race, and C-sump aft seals replacement. e.

Replace No. 6R bearing inner race as follows: (1)


(2)


(3)

Remove No. 6R bearing inner race and rotating air seal from power turbine forward shaft as follows: (a) Using pointed tool and needle nose pliers, remove retaining ring (3, figure 2). (b) Using pointed tool and needle nose pliers, remove retaining ring (2). (c) Install No. 6R bearing spanner nut wrench, 1C6856, antitorque tube (6, figure 3) into power turbine rotor forward shaft (5), engaging lugs on tube to cutouts on forward face of shaft. (d) Install No. 6R bearing spanner nut wrench, 1C6856, torque wrench (2) over antitorque tube (6). Ensure slots in torque wrench engage slots in No. 6R bearing spanner nut (3). (e) Install Sweeny torque multiplier, Model 8100 (1), onto No. 6R bearing spanner nut wrench, 1C6856, torque wrench (3), with antitorque lugs facing forward (away from rotor). (f) Place antitorque plate (7) over square shaft on front of antitorque tube (6) and against Sweeny torque multiplier, Model 8100 (1), so that holes in antitorque plate fit over antitorque lugs of Sweeny torque multiplier, Model 8100. Secure antitorque plate (7) with knurled screws. Position antiturn bar in antitorque plate (7). (g) Place square drive wrench in Sweeny torque multiplier, Model 8100 (1), input and turn counterclockwise to remove No. 6R bearing spanner nut (3). (h) Remove antiturn bar, antitorque plate (7), Sweeny torque multiplier, Model 8100 (1), and No. 6R bearing spanner nut wrench, 1C6856, torque wrench (2), after No. 6R bearing spanner nut turns freely. (i) Remove No. 6R bearing spanner nut (3) by hand.




Figure 2. No. 6R Bearing Inner Race and Rotating Oil Seal

Figure 3. No. 6R Bearing Spanner Nut Wrench, 1C6856 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 4. No. 6R Bearing Inner Race and Rotating Oil Seal Puller, 1C5691 WARNING DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW-TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. (j)

Using dry ice, chill power turbine forward shaft (6, figure 4) for approximately 20 minutes. Place bag of dry ice inside forward shaft. Remove dry ice.

(k) Install, No. 6R bearing inner race and rotating oil seal puller, 1C5691, barrel halves (2) around power turbine rotor forward shaft, so lip engages notch in rotating oil seal (5). (l) Insert No. 6R bearing inner race and rotating oil seal puller, 1C5691, pilot assembly (7) into power turbine rotor forward shaft (6). (m) Install No. 6R bearing inner race and rotating oil seal puller, 1C5691, large ring (3) over puller barrel halves (2) to hold them in place. (n) Attach Enerpac hydraulic pump to No. 6R bearing inner race and rotating oil seal puller, 1C5691, hydraulic inlet port (1).




•


•


(o) Using Enerpac hydraulic pump No. 6R bearing inner race and rotating oil seal puller, 1C5691, remove No. 6R bearing inner race and rotating oil seal. Handle No. 6R bearing inner race per GEK 105054, Chapter 10. (4)

Install No. 6 bearing inner race and rotating oil seal onto power turbine forward shaft as follows: (a) Heat No. 6R bearing inner race and rotating oil seal in 350°F (176°C) oven for approximately 20 minutes. WARNING

DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. (b) Using dry ice, chill power turbine forward shaft for approximately 20 minutes. Place bag of dry ice inside forward shaft. WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (c) Remove No. 6 bearing inner race and oil seal from oven. WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING COLD PARTS. (d) Remove dry ice from power turbine rotor forward shaft. (e) Using No. 6R bearing and seal race pusher, 1C5702, seat No. 6 bearing inner race and rotating oil seal as follows: 1

Install No. 6 bearing rotating oil seal onto power turbine rotor forward shaft.

2

Thread pusher, 1C5702, onto power turbine forward shaft, threaded end aft.




Tighten pusher, 1C5702, using a 1/2-inch drive torque wrench. When No. 6 bearing rotating oil seal has cooled sufficiently, remove pusher, 1C5702. Check for proper seating.

4

Install No. 6 bearing inner race onto power turbine rotor forward shaft.

5

Thread pusher, 1C5702, onto power turbine rotor forward shaft, threaded end forward.

6

Tighten pusher, 1C5702, using a 1/2-inch drive torque wrench. When No. 6 bearing inner race has cooled sufficiently, remove pusher, 1C5702. Check for proper seating. WARNING

ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (f) Using isopropyl alcohol, clean power turbine rotor forward shaft (1, figure 2) threads and No. 6R bearing spanner nut (4) threads and contact face. (g) Using thread lubricant, coat power turbine rotor forward shaft (1) threads and No. 6R bearing spanner nut (4) threads and contact face. (h) Thread No. 6R bearing spanner nut (4) onto power turbine rotor forward shaft (1) as far as possible by hand. (i) Install No. 6R bearing spanner nut wrench, 1C6856, antitorque tube (6, figure 3) into power turbine rotor forward shaft (5), engaging lugs on tube to cutouts on forward face of forward shaft. (j)

Install No. 6R bearing spanner nut wrench, 1C6856, torque wrench (2) over antitorque tube (6). Ensure slots in torque wrench engage slots in No. 6R bearing spanner nut (3).

(k) Install Sweeny torque multiplier, Model 8100 (1), onto No. 6R bearing spanner nut wrench, 1C6856, torque wrench (2), with antitorque lugs facing forward (away from rotor). (l) Place antitorque plate (7) over square shaft on front of antitorque tube (6) and against Sweeny torque multiplier, Model 8100 (1), so that holes in antitorque plate fit over antitorque lugs of Sweeny torque multiplier, Model 8100 (1). Secure antitorque plate (7) with knurled screws. Position antiturn bar in antitorque plate (7).




EXERCISE EXTREME CARE WHEN USING TORQUE MULTIPLIER. IMPROPER USE CAN CAUSE EXTENSIVE DAMAGE TO ENGINE PARTS. DOUBLE CHECK ALL TORQUE CALCULATIONS BEFORE APPLYING TORQUE. (m) Place square drive wrench in Sweeny torque multiplier, Model 8100 (1), input. Turning input wrench clockwise, tighten No. 6R bearing spanner nut (3) to 309-341 lb ft (419-462 N⋅m) of torque. (n) Check for alignment of slot in No. 6R bearing spanner nut (3) with slot in power turbine rotor forward shaft (5). Slots are aligned when a scribe mark on the antitorque tube aligns with the scribe mark in any of the slots (sight holes) in the wrench. CAUTION DO NOT EXCEED 341 LB FT (462 N·M) OF TORQUE WHEN APPLYING FINAL TORQUE. FAILURE TO COMPLY COULD RESULT IN DAMAGE TO ENGINE. (o) If alignment is not correct, increase torque until alignment is achieved. Do not exceed 341 lb ft (462 N⋅m). (p) Remove antiturn bar, antitorque plate (7), Sweeny torque multiplier, Model 8100 (1), and No. 6R bearing spanner nut wrench, 1C6856, torque wrench (3). (q) Install retaining ring (2, figure 2) and retaining ring (3) into No. 6R bearing spanner nut (4). f.

Replace No. 6 stationary air and oil seals as follows: (1)

Remove No.6 bearing vent stationary seal (9, figure 5) and pressure balance stationary seal (10) from TMF as follows: (a) Remove 48 bolts (8) that secure No.6 bearing vent stationary seal (9) and pressure balance stationary seal (10)) to TMF. (b) Remove No.6 bearing vent stationary seal (9) and pressure balance stationary seal (10) from rear of TMF using lubricated jackscrews, 1C6804. Turn jackscrews in equal increments. Hold seals to prevent damage due to falling from TMF.

(2)

Install No.6 bearing vent stationary seal (9) and pressure balance stationary seal (10) onto TMF as follows: (a) Install alignment pins, 1C6898, in stationary seal flange of TMF.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (b) Using thread lubricant, lightly coat threads and contact faces of 48 bolts (8).

(c) Position No. 6 bearing stationary seal (9) and pressure balance stationary seal (10) over alignment pins. (d) Install several bolts (8), then remove alignment pins. (e) Using 48 bolts (8), secure stationary seals (9 and 10) to TMF. Tighten bolts to 33-37 lb in. (3.8-4.1 N⋅m) of torque. 9.

D-Sump Components Replacement. NOTE Replacement of D-sump components shall be accomplished at depot level. Field level maintenance is limited to power turbine replacement. a.

Replace power turbine per WP 302 00.

10. Power Turbine Stage 1 Nozzle Components Replacement. a.


b.

Replace power turbine stage 1 nozzle components as follows: (1)


(2)

Remove power turbine stage 1 nozzle segments (20, figure 5) from TMF as follows: NOTE

Power turbine stage 1 nozzle has 14 nozzle segments. (a) Remove bolt and nut (23 and 24) that secure power turbine stage 1 nozzle segment (20) to power turbine nozzle support (6). (b) Remove retaining clip (18) and flat washer (19) that secure power turbine stage 1 nozzle segment (20) to power turbine stage 1 nozzle support (1). (c) Pull power turbine stage 1 nozzle segment (20) radially outward to remove from power turbine nozzle support (6) and power turbine stage 1 nozzle support (1). (d) Remove inner and outer seals (22 and 21) from power turbine nozzle segment (20).



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (e) Repeat steps (a) through (d), as required, for remaining power turbine stage 1 nozzle segments (20).

(3)

Install power turbine stage 1 nozzle segments (20) as follows: (a) Align slot in power turbine stage 1 nozzle segment (20) with pin on power turbine stage 1 nozzle support (1). (b) Install power turbine stage 1 nozzle segment (20) onto power turbine stage 1 nozzle support (1). Ensure inner flange of power turbine stage 1 nozzle segment engages in power turbine nozzle support (6). (c) Using retaining clip (18) and flat washer (19), secure power turbine stage 1 nozzle segment (20) to power turbine stage 1 nozzle support (1). (d) Using nonmetallic hammer, install inner and outer nozzle seals (21 and 22) into power turbine stage 1 nozzle segment (20). (e) Install bolt and nut (23 and 24) that secure power turbine stage 1 nozzle segment (20) to power turbine nozzle support (6). Tighten bolt to 55-70 lb in. (6.3-7.9 N⋅m) of torque. (f) Repeat steps (a) through (e), as required, for remaining power turbine stage 1 nozzle segments (20).




Figure 5. Power Turbine Stage 1 Nozzle 15/(16 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES SIX STAGE POWER TURBINE STATOR CASINGS REMOVAL AND INSTALLATION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - PK MODEL


Change No.

Page No.

Change No.

Page No.

Change No.


Page

Power Turbine Stator Casings Installation. ...................................................................... 12 Power Turbine Stator Casings Removal. ........................................................................... 3 Upper Power Turbine Stator Casing Installation. ............................................................ 26 Upper Power Turbine Stator Casing Removal. ................................................................. 24


GEK 105054 Volume II WP 218 00 1.


Introduction. This work package provides instructions for the removal and installation of LM2500+ Model PK gas turbine upper and lower stator casings from the six stage power turbine. It also provides instructions for removal of the upper stator casing only, as an alternate method of opening the power turbine.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Power Turbine Speed Transducer Lead Replacement Accelerometer Replacement Gas Turbine External Piping and Wiring Removal and Installation Power Turbine Forward Adapter Replacement Gas Turbine Assembly Replacement Maintenance Dolly Usage Six Stage Power Turbine Components Inspection Six Stage Power Turbine Rotor Stage 1 and Stage 6 Blade Inspection

GEK 105054 WP 002 00 WP 106 00 WP 111 00

WP 422 00


Part No.

Fixture, Lift - Low Pressure Turbine Stator, Lower Jack, Lowering - Engine Components Fixture, Drive - Low Pressure Turbine Rotor Case, Dummy - Low Pressure Turbine Stator Fixture, Hinge - Low Pressure Turbine Stator Case Fixture, Lift and Support - Low Pressure Turbine Stator Case, Upper Fixture, Lift - Low Pressure Turbine Stator, Upper Sweeny Torque Multiplier

1C5634G01 1C5654G03 1C6868G03 1C6871G01 1C8032G03


1C8042G01 1C8322G01 Model 8200 or equivalent

Nomenclature




Sealant Thread Lubricant 5.

SWP 113 01 WP 220 00 WP 300 00 WP 303 00 WP 421 00





Power Turbine Stator Casings Removal. a.

Comply with all instructions contained in WP 002 00. NOTE To access power turbine rotor, instructions for removal and installation of upper power turbine stator casing is provided in paragraphs 8 and 9.

b.

Disconnect high speed coupling shaft from power turbine forward adapter per packager’s manual.

c.

If required, remove gas turbine from enclosure per WP 300 00.

d.

If gas turbine is removed from enclosure, install into maintenance dolly, 1C9372, per WP 303 00.

e.

Remove power turbine forward adapter per WP 220 00.

f.

If installed, remove heat diffuser from No. 7 bearing aft stationary air seal flange per packager’s manual.

g.

Remove external tubing, piping, and securing hardware (figure 1) as follows: (1)

Remove balance piston air tube per SWP 113 01.

(2)

Remove D-sump vent tube per SWP 113 01.

(3)

Remove D-sump pressurization tube per SWP 113 01. WARNING


Remove D-sump lube oil supply tube per SWP 113 01.

(5)

Remove D-sump scavenge tube per SWP 113 01. NOTE

It is not necessary to disconnect power turbine speed transducer leads from power turbine speed transducers. h.

Remove power turbine speed transducer leads from flange bracket and loop clamps per WP 106 00.




Figure 1. Power Turbine External Piping and Tubing 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines i.

Remove accelerometer from turbine rear frame (TRF) flange per WP 111 00.

j.

Using marking pen, matchmark horizontal split-line of power turbine stator casing on circumferential flange of turbine mid frame (TMF) and TRF.

k.

Using marking pen, position mark all bracket locations on following flange locations: (1)

Mark bracket locations on TRF-power turbine upper stator casing flange.

(2)

Mark bracket locations on TMF-power turbine upper stator casing flange.

(3)

Mark bracket locations on left and right power turbine stator casing horizontal splitline flanges. CAUTION

DRIVE BODY-BOUND BOLTS OUT WITH PLASTIC MALLET. DO NOT USE WRENCH TO TURN BODY-BOUND BOLTS, OR DAMAGE TO POWER TURBINE STATOR CASINGS SHALL OCCUR. NOTE

l.

•

Remove body-bound bolt in bolthole 2 prior to removing bolt in bolthole 1. Remove all other body-bound bolts last.

•

Body-bound bolts are located in boltholes 2, 14, and 30 on both left and right power turbine stator casing horizontal split-line flange.

Remove horizontal split-line flange bolts (figure 2) as follows: (1)

Remove all horizontal split-line shear bolts, bolts, and self-locking nuts.

(2)

Using plastic mallet, drive body-bound bolts out of power turbine stator casing horizontal split-line flange.

(3)

Remove two brackets from horizontal split-line flange on right side, aft looking forward, of power turbine.




Figure 2. Power Turbine Casing Split-Line Flange 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines m. Remove upper power turbine stator casing as follows: CAUTION

UPPER AND LOWER POWER TURBINE STATOR CASINGS ARE MATCHED SETS. IF REPLACEMENT OF EITHER UPPER OR LOWER SECTION IS REQUIRED, BOTH CASINGS SHALL REQUIRE REPLACEMENT. (1)

Remove circumferential flange bolts and nuts that secure upper power turbine stator casing to TMF. Remove brackets.

(2)

Remove circumferential flange bolts and nuts that secure upper power turbine stator casing to TRF. Remove brackets. NOTE

Lift and support fixture, 1C8042, is comprised of four jacks. Jacks are identified as to their installation locations. (3)

Install lift and support fixture, 1C8042, to four locations on TMF and TRF circumferential flanges as follows: (a) Install jacks to inside side of TMF and TRF flange at horizontal split-line (figure 3). CAUTION

ENSURE DOWEL PINS ENGAGE ONLY UPPER POWER TURBINE STATOR CASING FLANGE, NOT TMF OR TRF FLANGES. (b) Engage dowel pins in upper power turbine stator casing holes. Secure jack to lower power turbine stator casing flange with bolts and nuts. Tighten bolts and nuts hand-tight. NOTE

•

Ensure jack handles are turned equal amounts to prevent binding of upper power turbine stator casing during opening.

•

Prior to raising upper power turbine stator casing, make visual inspection to ensure all attaching hardware has been removed. (c) Using handles, rotate both knurled nuts simultaneously. Raise upper power turbine stator casing to maximum height of 1.0 inch (25.4 mm).




Figure 3. Lift and Support Fixture, 1C8042

(4)

Install upper power turbine stator casing lift fixture, 1C8322 (figure 4), as follows: (a) Position aft plate (4) so pins in OTHER LM2500 side will engage boltholes in power turbine stator casing. (b) Using adjustment knob (3), move aft plate (4) to inward stop. (c) Position forward plate (1) so pins (5) engage power turbine forward flange boltholes. (d) Using adjustment knob (3), position aft plate (4) so pins (9) engage power turbine aft flange boltholes. (e) Using screws (6 and 10), flat washers (7 and 11), and nuts (8 and 12), secure upper power turbine stator casing lift fixture, 1C8322, to upper power turbine stator casing. Tighten screws hand-tight.

(5)

Attach hoist to upper power turbine stator casing lift fixture, 1C8322, lifteye (2).

(6)

Remove lift and support fixture, 1C8042, jacks from power turbine.




Figure 4. Upper Power Turbine Stator Casing Lift Fixture, 1C8322 9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (7) n.

Using hoist and upper power turbine stator casing lift fixture, 1C8322, lift and remove upper power turbine stator casing.

Install dummy power turbine stator case, 1C6871 (figure 5), onto TRF and TMF flanges at 12:00 o'clock position as follows: CAUTION USE CARE WHEN INSTALLING DUMMY POWER TURBINE STATOR CASE, 1C6871. DAMAGE TO NO. 7 BEARINGS MAY RESULT FROM TRF TILTING.

o.

(1)

Using adjustment nut (3), adjust forward and aft supports (4 and 2) to approximate power turbine stator casing length.

(2)

Using slave hardware, attach aft plate (1) to TRF flange. Tighten hardware hand-tight.

(3)

Using adjustment nut (3), move forward plate (5) so it engages TMF flange.

(4)

Using slave hardware, attach forward plate (5) to TMF flange. Tighten hardware hand-tight.

Remove lower power turbine stator casing as follows: CAUTION

•

UPPER AND LOWER POWER TURBINE STATOR CASINGS ARE MATCHED SETS. IF REPLACEMENT OF EITHER UPPER OR LOWER SECTION IS REQUIRED, BOTH CASINGS SHALL REQUIRE REPLACEMENT.

•

IF UPPER POWER TURBINE STATOR CASING IS REMOVED, DO NOT REMOVE LOWER POWER TURBINE STATOR CASING UNLESS DUMMY POWER TURBINE STATOR CASE, 1C6871, IS PROPERLY INSTALLED.

(1)

Place lift fixture, 1C5634, on lowering jack, 1C5654. Align lowering jack and lift fixture beneath lower power turbine stator turbine casing.

(2)

Raise lowering jack, 1C5654, until lift fixture, 1C5634, contacts lower power turbine stator casing. Ensure lowering jack and lift fixture are stable and properly fitted to lower power turbine stator casing.




Figure 5. Dummy Power Turbine Stator Case, 1C6871 11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


7.


(3)

Apply floor locks on lowering jack, 1C5654, to prevent movement of jack.

(4)

Remove circumferential flange bolts and nuts that secure lower power turbine stator casing to TMF. Remove brackets.

(5)

Remove circumferential flange bolts and nuts that secure lower power turbine stator casing to TRF. Remove brackets.

(6)

Using lowering jack, 1C5654, and lift fixture, 1C5634, remove lower power turbine stator casing from power turbine.

(7)

Release floor locks on lowering jack, 1C5654. Roll lowering jack, lift fixture, 1C5634, and lower power turbine stator casing away from gas turbine.

(8)

Remove lower power turbine stator casing from lift fixture and place on skid. Cover lower power turbine stator casing to prevent damage.

p.

Install dummy power turbine stator case, 1C6871, at 6:00 o'clock position per step n.

q.

Inspect power turbine stator casings and TRF per WP 421 00.

r.

Inspect power turbine stage 1 rotor blade shrouds per WP 422 00.

Power Turbine Stator Casings Installation. CAUTION ENSURE SUPPORTS OF LIFT FIXTURE DO NOT CONTACT NOZZLE LOCK PINS OF POWER TURBINE STATOR CASING. a.

Install lower power turbine stator casing as follows: (1)

Install lift fixture, 1C5634, onto lowering jack, 1C5654. Apply floor locks on lowering jack to prevent movement of jack.

(2)

Place lower power turbine stator casing on lift fixture, 1C5634. Ensure lower power turbine stator casing is level and not tilted to either side. WARNING


Using isopropyl alcohol, clean mating flanges to remove any debris.




Apply thin coat of sealant to forward and aft circumferential flanges inner sealing surfaces (figure 6).

(5)

Release floor locks on lowering jack, 1C5654, and roll lift fixture, 1C5634, and lower power turbine stator casing under power turbine. Roughly align lower power turbine stator casing with power turbine.

(6)

Remove slave hardware that secures dummy power turbine stator case, 1C6871, to TMF and TRF flanges at 6:00 o'clock position.

(7)

Remove dummy power turbine stator case, 1C6871.

(8)

Engage lowering jack, 1C5654, floor locks to prevent movement of lowering jack. WARNING

WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY. (9)

Raise lower power turbine stator casing into position by raising lowering jack.

Figure 6. Power Turbine Casing Sealant Application




(10) Check horizontal flange bolthole alignment. Release floor locks on lowering jack, 1C5654, and carefully position lower power turbine stator casing, if required. Flange should be even with matchmarks on TMF and TRF flanges. (11) Temporarily install approximately every third bolt and self-locking nut to forward and aft circumferential flanges. Install bolts as follows: (a) Install TMF-power turbine stator casing flange boltheads forward. (b) Install TRF-power turbine stator casing flange boltheads aft. (12) Tighten self-locking nuts finger-tight. Do not apply final torque. (13) Remove lowering jack, 1C5654, and lift fixture, 1C5634. b.

Install upper power turbine stator casing as follows: (1)

Install upper power turbine stator casing lift fixture, 1C8322, to upper power turbine stator casing per paragraph 6, step m. WARNING


Thoroughly clean mating flanges with isopropyl alcohol to remove any debris.

(3)

Apply thin coat of sealant to forward and aft flange inner sealing surface. Apply thin coat of sealant to lower power turbine stator casing horizontal split-line flange inner sealing surfaces.

(4)

Remove slave hardware that secures dummy power turbine stator case, 1C6871, to TMF and TRF flanges at 12:00 o'clock positions.

(5)

Remove dummy power turbine stator case, 1C6871. WARNING


Using hoist, carefully lift upper power turbine stator casing and lift fixture into position between TMF and TRF. Lower onto lower power turbine stator casing horizontal split-line flange. Align boltholes.




Temporarily install approximately every third bolt and nut to forward and aft circumferential flanges. Install bolts as follows: (a) Install TMF-power turbine stator casing flange boltheads forward. (b) Install TRF-power turbine stator casing flange boltheads aft.

c.

(8)

Tighten self-locking nuts finger-tight. Do not apply final torque.

(9)

Remove upper power turbine stator casing lift fixture, 1C8322, from upper power turbine stator casing.

Install and torque horizontal flange bolts and brackets as follows: (1)

Lubricate body-bound bolts with thread lubricant. CAUTION

USE PLASTIC MALLET TO SEAT BODY-BOUND BOLTS. DO NOT USE WRENCH TO TURN BODY-BOUND BOLTS, OR DAMAGE TO POWER TURBINE STATOR CASING SHALL OCCUR. NOTE

•

Body-bound bolts are installed in boltholes 2, 14, and 30 of left and right power turbine horizontal split-line flanges.

•

It may be necessary to use slave bolts and nuts to seat horizontal flanges.

(2)

Install body-bound-bolts. Do not install self-locking nuts at this time.

(3)

Lubricate bolts and shear bolts with thread lubricant.

(4)

Install bolts and shear bolts into boltholes per table 1.

(5)

Install self-locking nuts to all bolts, shear bolts, and body-bound bolts. Tighten self-locking nuts finger-tight.

(6)

Tighten self-locking nuts to finger-tight as follows: (a) Tighten self-locking nuts on body-bound bolts in bolthole 2, 14, and 30, alternating sides, working aft. Do not tighten to final torque. (b) Tighten all shear bolts and bolts, alternating sides, working aft. Visually check to ensure radial and axial alignment of upper and lower power turbine stator casings. Do not tighten to final torque.

(7)

Remove 10 bolts and self-locking nuts from No. 7 bearing aft stationary air seal (6, figure 7). Match pattern of adapter plate (2) boltholes.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Horizontal Split-Line Bolt Placement Bolthole Location

Final Torque

Right

15 through 23, 25, 28, 29, 31 15 through 26, 28, 29, 31 24 and 26

Machine

Left

27

0.250-28

Machine

Right

10 and 12

0.250-28

Machine

Left

6

0.3125-24

Body-Bound

Right

2

0.3125-24

Body-Bound

Left

2

0.375-24

Machine

Right

1

0.375-24

Machine

Left

1

0.3125-24

Machine

Right

7 through 9, 11, 13

0.3125-24

Machine

Left

7 through 13

0.3125-24

Body-Bound

Right

14

0.3125-24

Body-Bound

Left

14

0.250-24

Body-Bound

Right

30

0.250-24

Body-Bound

Left

30

0.3125-24

Machine

Right

3 through 5

0.3125-24

Machine

Left

3 through 5

80-90 lb in. (9.1-10.1 N⋅m) 80-90 lb in. (9.1-10.1 N⋅m) 80-90 lb in. (9.1-10.1 N⋅m) 80-90 lb in. (9.1-10.1 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m) 276-304 lb in. (31.2-34.3 N⋅m) 276-304 lb in. (31.2-34.3 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m) 80-90 lb in. (9.1-10.1 N⋅m) 80-90 lb in. (9.1-10.1 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m) 162-178 lb in. (18.4-19.6 N⋅m)

Bolt Size

Bolt Type

Side

0.250-28

Machine

Right

0.250-28

Machine

Left

0.250-28

Machine

0.250-28




Figure 7. Power Turbine Rotor Drive Fixture, 1C6868 17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



(8)

Install power turbine rotor drive fixture, 1C6868, drive shaft (1) into power turbine rotor aft shaft (7).

(9)

Install power turbine rotor drive fixture, 1C6868, adapter plate (2) over drive shaft (1). Align boltholes in adapter plate with boltholes in No. 7 bearing aft stationary air seal (6).

(10) Using 10 bolts (3) and nuts (4), secure power turbine rotor drive fixture, 1C6868, adapter plate (2) to No. 7 bearing aft stationary air seal (6). Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. (11) Install torque multiplier, Sweeny Model 8200, onto drive shaft (1) and adapter plate (2). WARNING PRESSURE OF 100 PSIG EXISTS IN THE SUPPLY LINES. RELIEVE PRESSURE TO PREVENT INJURY WHEN DISCONNECTING FITTINGS. (12) Attach air drive gun to torque multiplier. Attach shop air supply to air drive gun. (13) Using shop air supply and air drive gun, rotate power turbine rotor. CAUTION DO NOT TURN BODY-BOUND BOLTS; APPLY TORQUE TO NUTS ONLY, OR DAMAGE TO POWER TURBINE STATOR CASINGS SHALL OCCUR. NOTE Body-bound bolts are installed in boltholes 2, 14, and 30 of left and right power turbine horizontal split-line flanges. (14) While power turbine rotor is turning, gradually tighten bolts in horizontal split-line flanges. If rotation of power turbine rotor stops, loosen bolts until rotor starts turning and continue tightening other bolts. Continue tightening bolts until horizontal split-line flanges are together. (15) After all bolts are tight, and power turbine rotor is turning freely, shut off air gun. Remove air gun, torque multiplier, and power turbine rotor drive fixture, 1C6868. (16) Using thread lubricant, lubricate threads of 10 bolts and self-locking nuts used to secure No. 7 bearing aft stationary air seal (6) to TRF (5).




(17) Install 10 bolts and nuts into No. 7 bearing aft stationary air seal flange. Tighten bolts to 55-70 lb in. (6.3-7.9 N⋅m) of torque. (18) Remove bolts from power turbine on right, aft looking forward, horizontal split-line flange bolthole numbers 10, 12, 24, and 26. (19) Install two brackets onto power turbine right, aft looking forward, horizontal split-line flange. Secure using four bolts. Tighten bolts hand-tight. (20) Tighten all horizontal split-line flange bolts to final torque per table 1, alternating sides, working aft. d.

Install bolts, spacers, and brackets onto TMF flange per as follows: (1)

Apply thread lubricant sparingly to bolt threads.

(2)

Align brackets onto flange as follows: (a) If installing same power turbine stator casings removed in paragraph 6., align brackets per matchmarks made during removal. (b) If new power turbine stator casings are being installed, align brackets per table 2 and figure 8.

e.

f.

(3)

Install spacers onto bolts to be installed in boltholes 1 through 7, 10 through 16, 19 through 22, 24, 26, 30 through 35, 38 through 44, 47 through 51, 55, 59 through 63, 66 through 71, 74 through 80, 84, 86, 88 through 90, 96 through 100, and 103 through 108.

(4)

Install bolts, boltheads aft, and secure with self-locking nuts. Tighten self-locking nuts finger-tight.

Install brackets on aft side of TRF flange as follows: (1)

Align brackets onto flange per table 3 and figure 9.

(2)

Install bolts, boltheads forward, and secure with nuts. Tighten nuts finger-tight.

Tighten all TMF circumferential flange bolts as follows: (1)

Tighten bolt at top vertical centerline to 190-230 lb in. (21.5-25.9 N⋅m) of torque.

(2)

Tighten bolt at bottom vertical centerline to 190-230 lb in. (21.5-25.9 N⋅m) of torque.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. TMF Flange Brackets

Bracket 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Side of Flange Forward Aft Forward Forward Forward Forward Aft Forward Forward Forward Forward Aft Forward Forward Forward Forward Forward Aft Forward

Tab Facing Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft Aft

Table 3. TRF Flange Brackets Bracket 1 2 3 4 5 6 7 8 9 10 11 12

Side of Flange

Tab Facing

Aft Aft Aft Aft Forward Aft Aft Forward Forward Aft Aft Forward

N/A N/A Forward N/A Forward Aft N/A Forward Forward N/A N/A Forward




Figure 8. TMF Flange Brackets 21 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 9. TRF Flange Brackets 22 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


g.

h.


(3)

Index clockwise, aft looking forward, one bolt from top vertical centerline. Tighten bolt to 80-90 lb in. (9.1-10.1 N⋅m) of torque.

(4)

Index clockwise, aft looking forward, one bolt from bottom vertical centerline. Tighten bolt to 80-90 lb in. (9.1-10.1 N⋅m) of torque.

(5)

Repeat substeps (3) and (4) until all TMF flange bolts are tightened to final torque.

Tighten all TRF circumferential flange bolts as follows: (1)

Tighten bolt at top vertical centerline to 80-90 lb in. (9.1-10.1 N⋅m) of torque.

(2)

Tighten bolt at bottom vertical centerline to 80-90 lb in. (9.1-10.1 N⋅m) of torque.

(3)

Index clockwise, aft looking forward, one bolt from top vertical centerline. Tighten bolt to 80-90 lb in. (9.1-10.1 N⋅m) of torque.

(4)

Index clockwise, aft looking forward, one bolt from bottom vertical centerline. Tighten bolt to 80-90 lb in. (9.1-10.1 N⋅m) of torque.

(5)

Repeat substeps (3) and (4) until all TRF flange bolts are tightened to final torque.

Install tubing, piping, and hardware (figure 1) as follows: (1)

Install balance piston air tube per SWP 113 01.

(2)

Install D-sump vent tube per SWP 113 01.

(3)

Install D-sump pressurization tube per SWP 113 01. WARNING


Install D-sump lube oil supply tube per SWP 113 01.

(5)

Install D-sump scavenge tube per SWP 113 01.

i.

Install power turbine speed transducer leads per WP 106 00.

j.

Install accelerometer at TRF flange per WP 111 00.




k.

If removed, install heat diffuser onto No. 7 bearing aft stationary air seal flange per packager’s manual.

l.

Install power turbine forward adapter per WP 220 00.

m. If required, remove gas turbine from maintenance dolly, 1C9372, per WP 303 00.

8.

n.

If required, install gas turbine into enclosure WP 300 00.

o.

Connect high speed coupling shaft to power turbine forward adapter per packager’s manual.

Upper Power Turbine Stator Casing Removal. a.

Perform steps a. through l. of paragraph 6.

b.

Using lift and support fixture, 1C8042, break upper power turbine stator casing loose per paragraph 6. step m.

c.

Open power turbine stator case as follows: (1)

Install hinge fixtures, 1C8032, with hinges (figure 10) onto right side of power turbine. NOTE

Hinges are marked as to installation location. (2)

Install forward hinge to horizontal split-line flange, starting at third hole from forward flange. Install aft hinge in aft four holes of power turbine stator casing horizontal flange.

(3)

Install lifting handle to left power turbine stator casing horizontal split-line flange. Align foremost bolthole of lift handle with third bolthole from TMF flange.

(4)

Secure stanchion bracket to power turbine stator casing circumferential flanges at boltholes 3 and 6 on forward flange and boltholes 2 and 4 on aft flange.

(5)

Remove nuts and bolts that secure lift and support fixture, 1C8042. Remove lift fixture jacks.




Figure 10. Hinge Fixture, 1C8032 25 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



9.

•

WHEN WORKING ON OPEN POWER TURBINE SECTION, EXTREME CARE SHALL BE USED TO AVOID DROPPING ANY OBJECT INTO THE POWER TURBINE. REMOVE ALL OBJECTS FROM SHIRT POCKETS.

•

DO NOT LAY TOOLS OR PARTS ON HORIZONTAL FLANGES. SHOULD ANY OBJECT BE ACCIDENTALLY DROPPED INTO POWER TURBINE, STOP ALL OPERATIONS IMMEDIATELY AND REMOVE OBJECT.

•

DO NOT LEAVE POWER TURBINE UNATTENDED WHILE UPPER POWER TURBINE STATOR CASING IS REMOVED UNLESS OPEN SECTION IS PROPERLY COVERED.

(6)

Using lift handle, raise upper power turbine stator casing.

(7)

When upper power turbine stator casing is open to desired height, align hole in stanchion with bolthole in TRF and TMF flange. Install pin through stanchion and TRF and TMF flange bolthole.

d.

Inspect power turbine stator casings and TRF per WP 421 00.

e.

Inspect power turbine stage 1 rotor blade shrouds per WP 422 00.

Upper Power Turbine Stator Casing Installation. a.

Close upper power turbine stator casing as follows: WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. (1)

Using clean cloth and isopropyl alcohol, clean TMF and TRF flanges and circumferential upper power turbine stator casing flange.

(2)

Remove pins from hinge fixture, 1C8032, stanchions and power turbine stator casing. Lower upper power turbine stator casing.

(3)

Install lift and support fixture, 1C8042, jacks per paragraph 6, step m. CAUTION

DO NOT INTERCHANGE TOOLING BOLTS WITH POWER TURBINE BOLTS. (4)

Using jacks, remove weight from hinge fixture, 1C8032.




Remove hinge fixture 1C8032, from power turbine horizontal split-line flanges. Ensure mounting hardware is retained with hinge fixture to avoid intermixing tooling and power turbine hardware.

(6)

Apply thin coat of sealant to inner sealing surfaces of all flanges. NOTE

Ensure jack handles are turned equal amounts to prevent binding of upper power turbine stator casing during closing. (7)

b.

Using handle, turn lift and support fixture, 1C8042, jacks. Lower power turbine upper power turbine stator casing onto lower power turbine stator casing horizontal flange. Align boltholes in horizontal split-line flanges.

Perform steps c. through o. of paragraph 7.




WORK PACKAGE

TECHNICAL PROCEDURES SIX STAGE POWER TURBINE STAGE 1 ROTOR BLADE REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Power Turbine Stage 1 Rotor Blade Installation. ............................................................. Power Turbine Stage 1 Rotor Blade Removal.................................................................... Power Turbine Stage 1 Rotor Blade Selection. ..................................................................

4 3 4


1

GEK 105054 Volume II WP 219 00 1.


Introduction. This work package contains instructions for removal and installation of six stage power turbine stage 1 rotor blades from the LM2500+ Model PK gas turbine.

2.

3.

4.

5.

2


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Gas Generator Assembly Replacement Six Stage Power Turbine Stator Casings Removal and Installation Six Stage Power Turbine Stages 1 and 6 Rotor Blade Inspection Illustrated Parts Breakdown

GEK 105054 WP 002 00 WP 301 00 WP 218 00 WP 422 00 GEK 105055


Part No.

Tool Set, LPT Rotor Retainer Program, Balance - Blade Installation/Replacement

1C6702G01 9446M61G01



Shim Stock Marking Pen

Local Purchase Sharpie T.E.C. or Action Marker


IPB Figure No./Item

Retainer, Stage 1 Blade

68-2




Power Turbine Stage 1 Rotor Blade Removal. a.


b.

Separate gas generator and power turbine per WP 301 00 or packager's manual.

c.

Remove power turbine stator casings per WP 218 00.

d.

Using marking pen, position mark 166 power turbine stage 1 rotor blades.

e.

Using marking pen, position mark number 1 rotor blade dovetail slot on power turbine stage 1 rotor disk.

f.

Remove power turbine stage 1 rotor blade retainers as follows: CAUTION TO AVOID DAMAGE TO DOVETAIL SLOTS IN POWER TURBINE STAGE 1 ROTOR DISK, POSITION PRY BAR TOOL TO REACT AGAINST BLADE ROOT. (1)

Using pry bar, 9433M35, a component of tool set, 1C6702, bend power turbine stage 1 rotor blade retainer tang away from blade.

(2)

Using retainer pliers, 9433M34 (figure 1), a component of tool set, 1C6702, bend power turbine stage 1 rotor blade retainer tang back and forth. CAUTION

USE CAUTION TO AVOID DROPPING BLADE RETAINER.

g.

(3)

Remove and discard power turbine stage 1 rotor blade retainer.

(4)

Repeat steps (1) through (3) for remaining power turbine stage 1 rotor blade retainers.

Remove power turbine stage 1 rotor blades as follows: (1)

Using rubber mallet and nylon drift, tap all power turbine stage 1 rotor blades forward as set.

(2)

Tap consecutively around circumference of power turbine stage 1 rotor disk at stage 1 rotor blade base. Work all stage 1 rotor blades out evenly; do not attempt to remove only one rotor blade at time.

(3)

As power turbine stage 1 rotor blades are released from power turbine stage 1 rotor disk, remove stage 1 rotor blades and place into suitable container.


3

GEK 105054 Volume II WP 219 00 h. 7.

8.


Inspect power turbine stage 1 rotor blades per WP 422 00.

Power Turbine Stage 1 Rotor Blade Selection. a.

Measure and record weight of each power turbine stage 1 rotor blade.

b.

Measure and record weight of each replacement power turbine stage 1 rotor blade.

c.


Power Turbine Stage 1 Rotor Blade Installation. a.

Position power turbine stage 1 rotor blades partially into dovetail slots at forward side of power turbine stage 1 rotor disk while aligning power turbine stage 1 rotor blade shroud tip interlocks.

b.

Using nylon drift and rubber mallet, tap around dovetail circumference until power turbine stage 1 rotor blades are fully seated in power turbine stage 1 rotor disk.

c.

Install power turbine stage 1 rotor blade retainer as follows: (1)

Insert new power turbine stage 1 rotor blade retainer, prebent tang forward, under power turbine stage 1 rotor blade dovetail. Ensure prebent tang of stage 1 rotor blade retainer is seated against forward side of blade.

(2)

Use retainer pliers, 9433M34 (figure 1), a component of tool set, 1C6702, to prebend power turbine stage 1 rotor blade retainer tang aft of stage 1 rotor blade.

(3)

Position retainer bender tool, 9433M33, a component of tool set, 1C6702, onto bent power turbine stage 1 rotor blade retainer tangs. WARNING


4

Apply hydraulic pressure at 4,000 psig (27,579 kPa) to retainer bender tool, 9433M33. Pull back slightly on retainer bender tool to seat power turbine stage 1 rotor blade retainer tangs.




Figure 1. Installation of Power Turbine Stage 1 Rotor Blade Retainers (5)

Repeat substeps (1) through (4) for remaining power turbine stage 1 rotor blades.

(6)

Inspect for proper seating of power turbine stage 1 rotor blade retainers as follows: (a) Try to insert 0.015-inch (0.38 mm) shim stock between stage 1 rotor blade retainer and power turbine stage 1 rotor blade on both sides of power turbine stage 1 rotor disk. (b) If 0.015-inch (0.38 mm) maximum gap on each side of power turbine stage 1 rotor disk cannot be obtained, replace power turbine stage 1 rotor blade retainer. (c) Using white light and 2X (minimum) magnifying mirror, inspect power turbine stage 1 rotor blade retainer after each bending operation for cracks. Pay particular attention to areas of bend radii. No cracks allowed.

d.

Install power turbine stator casing per WP 218 00.

e.

Join power turbine to gas generator per WP 301 00 or packager's manual. Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

5/(6 Blank)



WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE FORWARD ADAPTER REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 10 ................. 0


Page

Forward Adapter Installation............................................................................................. Forward Adapter Removal..................................................................................................

8 3


GEK 105054 Volume II WP 220 00 1.


Introduction. This work package provides instructions on installation and removal of the power turbine forward adapter used to connect LM2500+ Model PK gas turbine to packager supplied drive components. For LM2500+ Model PV gas turbine applications, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title For LM2500+ Model PK gas turbine: Operation and Maintenance Manual, Volume II General Maintenance Practices Gas Turbine Assembly Replacement Power Turbine Assembly Replacement Maintenance Dolly Usage For LM2500+ Model PV gas turbine: Operation and Maintenance Manual Illustrated Parts Breakdown 3.

Nomenclature

Part No.

Torque Adapter-Forward Adapter, Coupling Nut Puller Shaft-Forward Adapter Multiplier, Torque

1C6364G02 1C8344G01 Sweeny Model 8100 or Model 8200 Local Purchase



Marking Pen

Sharpie T.E.C. or Action Marker Fed Spec BB-C-104 GE Spec A50TF201 or MIL-T-5544

Dry Ice Thread Lubricant 5.

GEK 105052 GEK 105053

Support Equipment.

Pump, Enerpac Hydraulic 4.

GEK 105054 WP 002 00 WP 300 00 WP 302 00 WP 303 00





Forward Adapter Removal. a.


b.

Remove gas turbine from enclosure per WP 300 00 or power turbine from enclosure per WP 302 00.

c.

If desired, install gas turbine or power turbine into maintenance dolly, 1C9372, per WP 303 00. NOTE Forward adapter coupling nut has standard right-hand threads.

d.

Remove forward adapter coupling nut as follows: NOTE Before inserting torque adapter, 1C6364, into shaft of forward adapter, ensure setscrew of retainer is backed off so sleeve block seats against retainer. (1)

Check to verify torque adapter, 1C6364, setscrew (6, figure 1) is backed off and sleeve block (7) is seated against retainer (5).

(2)

Carefully guide torque adapter, 1C6364, into shaft of forward adapter (13). Turn lock shaft slot (3) clockwise to lock torque adapter into forward adapter coupling nut.

(3)

Free coupling nut fingers from forward adapter (13) by threading setscrew (6) of retainer (5) until screw head is seated against retainer (5). NOTE

When installing antitorque plate to forward adapter, orient plate bosses at the 6:00 and 9:00 o'clock positions, and square drive socket in the plate at the 3:00 o'clock position. (4)

Install antitorque plate (1) over aft end of torque adapter, 1C6364, and seat against aft flange of forward adapter (13).

(5)

Using 16 bolts and nuts, secure antitorque plate (1) to forward adapter (13). Tighten nuts to 160-210 lb in. (18.1-23.7 N⋅m) of torque.

(6)

Install torque multiplier onto antitorque plate (1). Tighten two bolts against flats of torque multiplier retention pins (12).




Figure 1. Torque Adapter, 1C6364 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Install drive spline (4) onto square end of torque adapter, 1C6364, and splines of torque multiplier.

(8)

Install two handles (2) into drive spline (4).

(9)

Using torque multiplier, apply torque to forward adapter coupling nut. Use sufficient force to free adapter coupling nut from power turbine rotor aft shaft.

(10) Remove torque multiplier, antitorque plate (1), and torque adapter, 1C6364, with coupling nut attached, from forward adapter (13). (11) Prior to reuse, inspect coupling nut for serviceability. e.

Remove forward adapter from power turbine rotor aft shaft as follows: (1)

Install forward adapter shaft puller, 1C8344, pusher shaft (2, figure 2) into forward adapter and power turbine rotor aft shaft as follows: (a) Insert threaded end of pusher shaft (2) into center of forward adapter. CAUTION

USE CARE WHEN REMOVING PUSHER SHAFT FROM FORWARD ADAPTER TO AVOID DISLODGING PLASTIC GUIDE RINGS. (b) Slowly insert pusher shaft (2) into forward adapter. (c) Thread pusher shaft (2) into forward adapter until it engages threads of power turbine rotor aft shaft. (d) Continue threading pusher shaft (2) into power turbine rotor aft shaft until Dim A equals approximately 0.38-0.62 inches (9.7-15.7 mm). (2)

Position forward adapter shaft puller, 1C8344, puller plate (3) as follows: (a) If engine centerline is vertical, using hoist ring (12) and hoist, position puller plate (3) against aft flange of forward adapter. NOTE

The location of clamp halves (5 and 6) can be adjusted to position lift point over center of gravity. (b) If engine centerline is horizontal, proceed as follows: 1

Place clamps halves (5 and 6) around hydraulic cylinder (11).




Figure 2. Forward Adapter Shaft Puller, 1C8344 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



2

Using four capscrews (7) and nuts (8), secure clamp halves (5 and 6) together. Tighten capscrews to 160-210 lb in. (18.1-23.7 N⋅m) of torque.

3

Attach hoist to sling link (15).

4

Using hoist, position puller plate (3) against aft flange of forward adapter. CAUTION

USE ALL 48 BOLTS TO MEET APPLICABLE SAFETY REQUIREMENTS. (3)

Using 48 capscrews (9) and nuts (8), attach puller plate (3) to forward adapter flange. Tighten capscrews to 160-210 lb in. (18.1-23.7 N⋅m) of torques.

(4)

If applicable, using marking pen, matchmark forward adapter to power turbine rotor aft shaft.

(5)

Using marking pen, mark forward adapter per figure 2.

(6)

Using female coupling (13), connect hydraulic pump to hydraulic cylinder (11).

(7)

Using hydraulic pump, remove forward adapter from power turbine rotor aft shaft as follows: WARNING

SERIOUS INJURY CAN OCCUR WHEN APPLYING HYDRAULIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS. CAUTION APPLY 5,000 PSI (34,473 KPA) MAXIMUM OR DAMAGE TO TOOL AND ENGINE WILL OCCUR. (a) Using hydraulic pump, apply pressure to hydraulic cylinder (11). (b) Watch mark made in step (5). When mark has moved 1.6 inches (40.6 mm) aft, rabbet fit of forward adapter to power turbine rotor aft shaft has separated.




CONTINUED PRESSURIZATION WILL DISLODGE PLASTIC RING GUIDES FROM THEIR PROPER POSITION. (c) When rabbet fit of power turbine rotor aft shaft and forward adapter has separated, stop applying pressure to hydraulic cylinder (11). (8)

Remove forward adapter shaft puller, 1C8344, from forward adapter as follows: (a) Remove capscrews (9) and nuts (8) from pusher plate and forward adapter. (b) Using hoist attached to either sling link (15) or hoist ring (12), carefully remove hydraulic cylinder (11) and puller plate (3) from engine hardware. (c) Unthread pusher shaft (2) from power turbine rotor aft shaft and forward adapter. CAUTION

USE CARE WHEN REMOVING PUSHER SHAFT (2) FROM FORWARD ADAPTER TO AVOID DISLODGING PLASTIC GUIDE RINGS. (d) Slowly pull pusher shaft (2) aft out of forward adapter. f. 7.

Carefully pull forward adapter aft until clear of power turbine rotor aft shaft.

Forward Adapter Installation. WARNING DRY ICE, BB-C-104, IS EXTREMELY COLD AND CAN CAUSE SERIOUS LOW-TEMPERATURE BURNS. WEAR INSULATED GLOVES WHEN HANDLING MATERIAL. a.

Using dry ice, chill forward adapter stub-shaft for approximately 20 minutes.




Install forward adapter into power turbine rotor aft shaft as follows: WARNING WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING COLD PARTS. CAUTION EXERCISE CARE TO PRECLUDE DAMAGE TO MATING PARTS WHEN INSTALLING FORWARD ADAPTER TO POWER TURBINE AFT SHAFT. (1)

Slowly insert forward adapter stub-shaft into aft end of power turbine rotor aft shaft. Ensure splines on stub-shaft engage splines of power turbine rotor and that forward adapter is fully seated. NOTE

Forward adapter coupling nut has standard right-hand threads. (2)

Install forward adapter coupling nut into power turbine rotor aft shaft as follows: (a) Lubricate internal threads of forward adapter coupling nut with thread lubricant. (b) Install forward adapter coupling nut onto torque adapter, 1C6364. (c) Lock forward adapter coupling nut to torque adapter, 1C6364, by turning of lock shaft slot (3, figure 1) clockwise. (d) Depress fingers of forward adapter coupling nut and insert into shaft of power turbine rotor aft shaft. (e) Thread forward adapter coupling nut into power turbine rotor aft shaft.

(3)

Install antitorque plate (1) over aft end of torque adapter, 1C6364. Seat antitorque plate against aft flange of forward adapter (13).

(4)

Using 16 bolts and nuts, secure antitorque plate (1) to forward adapter (13). Tighten nuts to 160-210 lb in. (18.1-23.7 N⋅m) of torque.

(5)

Install torque multiplier onto antitorque plate (1). Secure by tightening two bolts against flats of torque multiplier retainer pins (12).

(6)

Install drive spline (4) onto square end of torque adapter, 1C6364, and splines of torque multiplier.


GEK 105054 Volume II WP 220 00 (7)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Install handle (2) into drive spline (4) of antitorque plate (1). CAUTION

EXERCISE EXTREME CARE WITH USE OF TORQUE MULTIPLIER. INCORRECT USAGE CAN CAUSE EXTENSIVE GAS TURBINE DAMAGE. DOUBLE CHECK ALL TORQUE CALCULATIONS PRIOR TO APPLICATION OF FORCE (VIA TORQUE MULTIPLIER) TO COUPLING NUT OF FORWARD ADAPTER. (8)

Recheck torque multiplier calculations to be sure correct force required shall not be exceeded.

(9)

Using torque multiplier, apply torque to forward adapter coupling nut. Tighten forward adapter coupling nut to 522-578 lb ft (707.9-783.7 N⋅m) of torque.

(10) Remove torque multiplier from antitorque plate (1). (11) Remove antitorque plate (1) from forward adapter (13). (12) Turn setscrew (6) of retainer (5) on torque adapter, 1C6364, counter-clockwise until sleeve block (7) can be moved aft to seat against retainer. NOTE This action will free coupling nut fingers from the wrench and allow the ratchet teeth of the coupling nut and stub-shaft to engage. (13) Engage ratchet teeth of forward adapter coupling nut as follows: (a) Unlock torque adapter, 1C6364, from forward adapter coupling nut by turning lock shaft slot (3) counterclockwise. (b) Remove torque adapter, 1C6364, from forward adapter (13). (14) Using flashlight, check forward adapter coupling nut ratchet teeth for full engagement with ratchet teeth of forward adapter (13). c.

If required, remove gas turbine or power turbine from maintenance dolly, 1C9372, per WP 303 00.

d.

Install gas turbine into enclosure per WP 300 00 or power turbine per WP 302 00.




WORK PACKAGE

TECHNICAL PROCEDURES LPT STAGE 1 NOZZLE ASSEMBLY REPLACEMENT (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC SERIES - ALL


Change No.

Page No.

Change No.

Page No.

Change No.


Subject LPT Stage 1 Nozzle Installation......................................................................................... LPT Stage 1 Nozzle Removal..............................................................................................

3 3


GEK 105054 Volume II WP 221 00 1.


Introduction.

This work package contains instructions for removal and installation of the low pressure turbine (LPT) stage 1 nozzle assembly. 2.


Number

Operation and Maintenance Manual, Volume II Power Turbine and Gas Generator Separation/Reassembly

GEK 105054

3.


4.


5.

WP 216 00

Nomenclature


Lubricating oil Thread lubricant Masking Tape Plastic

C02-023 C02-058 Local Purchase Local Purchase





LPT Stage 1 Nozzle Removal. a.

Remove the power turbine from the turbine mid frame (TMF). Refer to WP 216 00.

b.

Remove the 14 LPT stage 1 nozzles from the power turbine as follows. CAUTION ALL OPENINGS IN SUMP AREA IN AFT END OF TMF MUST BE COVERED WITH PLASTIC AND TAPE TO PREVENT PARTS FROM FALLING INTO OPEN CAVITIES. FAILURE TO DO THIS COULD RESULT IN DAMAGE TO GAS GENERATOR OR GAS TURBINE.

c. 7.

(1)

Remove 14 retaining clips (3, figure 1) that secure 14 stage 1 nozzles (1) and 14 washers (4) to stage 1 outer support ring (5).

(2)

Remove washers (4).

(3)

Remove 14 stage 1 nozzle strips (6) and 14 stage 1 nozzle strips (7) from forward and aft edges of nozzle (1) outer platforms. Discard strips.

(4)

Remove 14 nozzles (1) by pulling radially outward to disengage nozzles from pins in ring (5) and from stage 1 nozzle support.

(5)

Remove 14 stage 1 nozzle strips (8) and 14 stage 1 nozzle strips (9) from nozzles (1). Discard strips.

(6)

If necessary, remove 32 bolts (10) that secure stage 1 nozzle support (2) to TMF. Remove support.

Remove eight screws (11) and nuts (12) that secure ring (5), TMF aft outer seal (13), and ring spacer (14) to TMF. Remove ring, seal, and spacer from TMF.

LPT Stage 1 Nozzle Installation. a.

If removed, install the stage 1 nozzle support (2) as follows. Refer to figure 1. (1)

Apply thread lubricant, C02-058, to threads and seating surfaces of 32 bolts (10).

(2)

Position support (2) onto TMF.

(3)

Install 32 bolts (10) to secure support (2) to TMF. Tighten bolts in crisscross pattern to 95-105 lb in. (10.7-11.9 N⋅m) of torque.




Install stage 1 nozzles (1) as follows: CAUTION ALL OPENINGS IN SUMP AREA IN AFT END OF TMF MUST BE COVERED WITH PLASTIC AND TAPE TO PREVENT PARTS FROM FALLING INTO OPEN CAVITIES. FAILURE TO DO THIS COULD RESULT IN DAMAGE TO EQUIPMENT. (1)

Install one nozzle (1) at the 12:00 o’clock position of TMF by positioning hole in outside diameter of nozzle over pin of ring (5) and tang on nozzle into groove inside diameter of support (2).

(2)

Place washer (4) over pin in ring (5) and install retaining clip (3) with open end away from 12:00 o’clock position to secure nozzle (1) and washer to support. WARNING

LUBRICATING OIL, C02-023, IS COMBUSTIBLE AND AN IRRITANT. DO NOT INHALE, INGEST, OR LET THIS MATERIAL TOUCH YOU. PERSONAL PROTECTIVE EQUIPMENT IS REQUIRED. USE MECHANICAL EXHAUST VENTILATION. IF MECHANICAL EXHAUST VENTILATION IS NOT AVAILABLE, USE AN APPROVED RESPIRATOR. (3)

Apply lubricating oil, C02-023, to 14 stage 1 nozzle strips (8) and 14 stage 1 nozzle strips (9).

(4)

Install stage 1 nozzle strip (8) and stage 1 nozzle strip (9) into seal grooves in nozzle (1).

(5)

Continue installing nozzles (1), washers (4), retaining clips (3), and stage 1 nozzle strips (8 and 9) clockwise from the 12:00 o’clock position until all nozzles are installed. NOTE

Stage 1 nozzle strips (6 and 7) may be installed once all nozzles (1) are installed on TMF. (6)

Apply lubricating oil, C02-023, to 14 stage 1 nozzle strips (6) and 14 stage 1 nozzle strips (7).

(7)

Install stage 1 nozzle strips (7) into aft edges between nozzle (1) outer platforms. Push strips into slots until strips lock into place.

(8)

Install strips (6) into forward edges between nozzle (1) outer platforms. Install strips fully into slots so that strips are not protruding from edges of nozzles.




Remove plastic coverings and tape from TMF. CAUTION

FLAT HEADS OF SCREWS MUST SEAT IN COUNTERSINK PROVIDED AND MUST NOT PROTRUDE ABOVE SURFACE OF SUPPORT RING TO PREVENT EQUIPMENT DAMAGE. (10) Install eight screws (11) on the aft flange of the ring (5) and secure the ring (5), TMF aft outer seal (13), and ring spacer (14) to the TMF with eight nuts (12). (11) Tighten eight nuts (12) to 24-26 lb in. (2.7-2.9 N⋅m) of torque. (12) Wiggle each nozzle (1) to ensure nozzles are not bound.




Figure 1. TMF Assembly Aft Components - Six-Stage PT Configuration (Sheet 1 of 2) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. TMF Assembly Aft Components - Six-Stage PT Configuration (Sheet 2 of 2) 7/(8 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES GAS TURBINE ASSEMBLY REPLACEMENT (LEVEL 1 AND 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS PK AND PV


Change No.

Page No.

Change No.

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1 - 11 ................. 0 12 Blank............ 0 Alphabetical Index Subject

Page

Gas Turbine Installation..................................................................................................... 10 Gas Turbine Removal.......................................................................................................... 5


GEK 105054 Volume II WP 300 00 1.


Introduction. This work package contains instructions for removal and installation of LM2500+ Model PK gas turbine from the enclosure. If removing and installing LM2500+ Model PV gas turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown, for further instructions. NOTE Testing has demonstrated that failure to complete the following purge procedure will result in residual fuel within the gas turbine and fuel supply system and the engine cannot be declared Non-HAZMAT for shipping. Similarly, testing shows that, if the procedure is completed, the engine will be free of fuel and can be declared Non-HAZMAT. a.

Normal Shutdown and Cooldown. If the gas turbine including fuel system is to be removed from the enclosure in preparation for shipment by ground or air, complete the following fuel system drain and purge procedure. Fuel system removal prior to shipment does not require the purge procedure. (1)

While the engine is still in the enclosure, disconnect all fuel manifolds at the package supply interface. WARNING

LUBRICATING OIL, MIL-L-6081, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Liquid Fuel - If present, should be drained into a container or fuel drain tank when the fittings are opened. Any locations such as flow splitter, pressurization valve or flow divider should also be isolated and drained. As an alternative to ventilating, the liquid fuel system can be filled with MIL-L-6081, Grade 1010 slush oil. This alternative is preferred if the engine is to be stored for extended periods before or after service. (b) Gas Fuel - Open the fuel manifold fittings and allow them to ventilate into the enclosure. (2)

Using the Human Machine Interface (HMI), start the enclosure ventilation fan(s).

(3)

Initiate a Dry Crank (no fuel supply) using the HMI and allow the engine to ramp to 2200 rpm HP rotor speed for 10 minutes. This will ventilate any remaining fuel or vapor into the enclosure using compressor discharge air.

(4)

After 10-minute purge, stop dry crank.

(5)

Stop ventilation fan(s).

(6)

Complete gas turbine removal.




Emergency Shutdown or Engine Failure. If the gas turbine including fuel system is to be removed from the enclosure in preparation for shipment by ground or air, complete the following fuel system drain and purge procedure. Fuel system removal prior to shipment does not require the purge procedure. (1)

While the engine is still in the enclosure, disconnect all fuel manifolds at the package supply interface as well as at all nozzles or premixers.

(2)

Using the HMI, start the enclosure ventilation fan(s).

(3)

Drain and blow out all fuel lines. WARNING

LUBRICATING OIL, MIL-L-6081, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Liquid fuel - If present, should be drained into an approved container or the fuel drain tank when the fittings are opened. Any locations such as flow splitter, pressurization valve or flow divider should also be isolated and drained. As an alternative to ventilating, the liquid fuel system can be filled with MIL-L-6081, Grade 1010 slush oil. This alternative is preferred if the engine is to be stored for extended periods before or after service. 1

Open the combustor case drain fitting and drain any residual fuel into an approved container or the fuel drain tank. WARNING

WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS. 2

After all fuel is drained, blow out each of the lines, hoses and connections with shop air.

(b) Gas Fuel - Open the fuel manifold fittings and blow out each of the lines, hoses and connections with shop air. (4)


(5)

Reconnect fuel nozzles or premixers.

(6)

Complete gas turbine removal.


GEK 105054 Volume II WP 300 00 2.



Title

3.

4.

5.

For LM2500+ Model PK gas turbine: Operation and Maintenance Manual, Volume I Installation/ Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Replacement Ignition Exciter Replacement Gas Generator Speed Sensor Replacement Power Turbine Speed Transducer Lead Replacement High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Replacement Lube System Temperature Sensor Replacement Accelerometer Replacement Power Turbine Inlet Pressure (P5.4) Probe Replacement Gas Turbine Outside Piping and Wiring Removal and Installation Pneumatic Starter (Shrouded/Nonshrouded) Replacement Hydraulic Starter Replacement Hydraulic Pump Replacement High Pressure Compressor Discharge Temperature (T3) Sensor Replacement Gas Generator Inlet Duct Replacement Centerbody Replacement Power Turbine Forward Adapter Replacement Maintenance Dolly Usage Gas Generator/Gas Turbine Shipping For LM2500+ Model PV gas turbine: Operation and Maintenance Manual Illustrated Parts Breakdown Support Equipment.

GEK 105054 Chapter 7 GEK 105054 WP 002 00 WP 101 00 WP 104 00 WP 105 00 WP 106 00 WP 109 00 WP 110 00 WP 111 00 WP 112 00 SWP 113 01 WP 117 00 SWP 117 01 WP 120 00 WP 123 00 WP 204 00 WP 205 00 WP 220 00 WP 303 00 WP 502 00 GEK 105052 GEK 105053

Nomenclature

Part No.


1C8341G01



Lubricating Oil






Gas Turbine Removal. a.

Comply with all instructions contained in WP 002 00. CAUTION GAS TURBINE SHALL BE HANDLED CAREFULLY. ADEQUATE PRECAUTIONS SHALL BE TAKEN TO PREVENT DAMAGE TO EXTERNAL PIPING AND ELECTRICAL LEADS DURING HANDLING. DO NOT CLIMB OR STEP ONTO ANY PART OF TURBINE OR PIPING. NOTE Due to configuration differences of OEM-provided gas turbine enclosures, the following procedures may require modification. Refer to packager's manual.

b.

Remove inlet screen and inlet duct per WP 204 00.

c.

Remove centerbody per WP 205 00. WARNING

d.

•


•


Disconnect gas turbine outside piping and wiring per table 1 and SWP 113 01. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

e.

Disconnect all fuel, air, lube oil, and instrumentation service connections from gas turbine to enclosure. Refer to table 1 and packager’s manual. Drain all residual fluids into approved waste container.

f.

Prepare items listed in table 2 for engine shipment.

g.

Disconnect any associated accessories, as required, per packager’s manual.

h.

Remove fuel system, if required, per WP 101 00.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Gas Turbine Connections and Hardware

Item Gas turbine Fuel system components Igniter cable Gas generator speed sensors Power turbine speed transducer leads P2/T2 sensor

Item Enclosure Manifold to nozzle and packager connections Ignition exciter Packager leads Packager leads Packager tubing

Lube system RTDs Accelerometers

Packager leads Packager leads

P5.4 Pneumatic starter

Packager tubing Packager connections

Hydraulic starter

Packager connections

Hydraulic pump

Filter in line, filter out line, FMV line Packager lead

T3 sensor P2/T2 and VSV actuators electrical connections Lube and scavenge Pump VSV servovalve UV flame sensors T5.4 harness

Packager leads Packager lube oil supply and scavenge hoses Packager leads Packager leads Packager leads

Note N/A Refer to WP 101 00 and packager’s manual Refer to WP 104 00 Refer to WP 105 00 and packager’s manual Refer to WP 106 00 and packager’s manual Refer to WP 109 00 and packager’s manual Refer to WP 110 00 Refer to WP 111 00 and packager’s manual Refer to WP 112 00 Refer to WP 117 00 and packager’s manual Refer to SWP 117 01 and packager’s manual Refer to WP 120 00 and packager’s manual Refer to WP 123 00 and packager’s manual Refer to packager’s manual Refer to packager’s manual Refer to packager’s manual Refer to packager’s manual Refer to packager’s manual



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Gas Turbine Connections and Hardware Item Accelerometer - gas generator Accelerometer - power turbine P2/T2 sensor T3 sensor Optional T3 sensor Igniter Optional igniter Igniter lead(s) UV flame sensor brackets T5.4 probes T5.4 harnesses P5.4 sensor Power turbine speed transducer Gas generator speed transducer Lube system RTDs

Item

Note

N/A

Send with engine

N/A

Send with engine

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Send with engine Send with engine Retain with enclosure or send with engine Send with engine Send with engine Send with engine Send with engine Send with engine Send with engine Send with engine Send with engine

N/A

Send with engine

N/A

Send with engine NOTE

Use of lift fixture, 1C8341, is dependent on space within enclosure. If space is not sufficient to allow use of lift fixture, attach packager’s lift fixture per packager’s manual. i.

Secure high speed coupling shaft per packager’s manual.

j.

Disconnect gas turbine from exhaust system components per packager’s manual.

k.

Install lift fixture, 1C8341 (figure 1), onto gas turbine as follows: (1)

Ensure forward lifting plate is installed in PLUS lifting position on lift fixture.




Figure 1. Gas Turbine Lift Fixture, 1C8341 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



(2) Attach enclosure hoist onto lift fixture, 1C8341, hoist attachment points. (3) Raise lift fixture, 1C8341, and align over gas turbine. (4) Using two quick-release pins, attach lift fixture, 1C8341, forward links onto gas turbine forward handling mounts on compressor front frame (CFF). (5) Using two quick-release pins, attach lift fixture aft links onto gas turbine ground handling mounts on turbine rear frame (TRF). WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. l.

Carefully take up slack on enclosure hoist so weight of gas turbine is supported by hoist and lift fixture, 1C8341, and tension is relieved from enclosure engine mounts.

m. Disconnect and remove enclosure engine mounting hardware per packager’s manual. CAUTION

•

WHEN SEPARATING POWER TURBINE FROM HIGH SPEED COUPLING SHAFT, EXTREME CARE SHALL BE EXERCISED. USE VISUAL OBSERVATION OF BREAKPOINT TO ENSURE SMOOTH SEPARATION WITH NO EVIDENCE OF BINDING ON FORWARD ADAPTER COUPLING BOLTS.

•

ENSURE POWER TURBINE FORWARD ADAPTER IS MATCHMARKED TO HIGH SPEED COUPLING SHAFT PRIOR TO REMOVING.

n.

Carefully move gas turbine to enclosure door per packager’s manual.

o.

Install protective caps, plugs, or covers. Cover all openings to prevent entry of foreign objects and contamination.

p.

Attach overhead hoist to lift fixture, 1C8341. Take up slack to support lift fixture and gas turbine. Remove enclosure hoist from lift fixture. NOTE Gas turbine can be directly installed into shipping container without use of maintenance dolly, 1C9372, if desired.

q.

Install gas turbine into maintenance dolly, 1C9372, per WP 303 00 or shipping container per WP 502 00.


GEK 105054 Volume II WP 300 00 7.


Gas Turbine Installation. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. NOTE

•

Use of lift fixture, 1C8341, is dependent on space within enclosure. If space is not sufficient to allow use of lift fixture, attach packager’s lift fixture per packager’s manual.

•

Gas turbine can be directly installed into enclosure without use of maintenance dolly, 1C9372, if desired.

a.

Remove gas turbine from shipping container per WP 502 00, or maintenance dolly, 1C9372, per WP 303 00.

b.

If required, install forward adapter onto gas turbine per WP 220 00.

c.

If required, install fuel system per WP 101 00.

d.

Carefully move gas turbine to enclosure door. Connect enclosure hoist to lift fixture, 1C8341, per packager’s manual. Disconnect overhead hoist from lift fixture.

e.

Move gas turbine into enclosure per packager’s manual.

f.

If applicable, align matchmarks on forward adapter with high speed coupling shaft.

g.

Install attaching hardware between gas turbine forward shaft and high speed coupling shaft per packager’s manual.

h.

Install enclosure mounting hardware per packager’s manual.

i.

Connect power turbine to exhaust system components per packager’s manual.

j.

Remove hardware used to secure high speed coupling shaft per packager’s manual.

k.

Remove lift fixture, 1C8341, from gas turbine as follows: (1)

Remove two quick-release pins that attach lift fixture forward links to gas turbine forward handling mounts onto CFF.

(2)

Remove two quick-release pins that attach lift fixture aft links to gas turbine aft handling mounts onto TRF.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (3) l.

Using enclosure hoist, raise lift fixture, 1C8341, away from gas turbine.

Connect gas turbine outside piping and wiring between gas turbine and power turbine per table 1 and SWP 113 01.

m. Connect all fuel, air, lube oil, and instrumentation service connections from gas turbine to enclosure. Refer to table 1 and packager’s manual. n.

Connect any associated accessories, as required, per packager’s manual.

o.


p.

Inspect gas turbine air inlet duct area with strong light for foreign objects. Pay special attention to locations behind inlet guide vanes (IGV) and blisk blades at 6:00 o’clock position in CFF and 12:00 o’clock position on hub.

q.

Install inlet screen and inlet duct per WP 204 00.

r.

Perform installation checkout per packager’s manual.

s.

Perform functional and operational tests per GEK 105054, Chapter 7.




WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR ASSEMBLY REPLACEMENT (LEVEL 1 AND 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

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Page

Gas Generator Installation. ................................................................................................ 12 Gas Generator Removal. ..................................................................................................... 5


GEK 105054 Volume II WP 301 00 1.


Introduction. This work package contains instructions for removing and installing a LM2500+ Model GK gas generator onto a packager supplied power turbine, a LM2500+ Model PK gas generator onto a GE supplied power turbine, and a LM2500+ Model GV gas generator or Model PV gas turbine onto a two stage high speed power turbine. For LM2500+ Model GV gas generator or Model PV gas turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown, for additional instructions. NOTE Testing has demonstrated that failure to complete the following purge procedure will result in residual fuel within the gas generator and fuel supply system and the engine cannot be declared Non-HAZMAT for shipping. Similarly, testing shows that, if the procedure is completed, the engine will be free of fuel and can be declared Non-HAZMAT. a.

Normal Shutdown and Cooldown. If the gas generator including fuel system is to be removed from the enclosure in preparation for shipment by ground or air, complete the following fuel system drain and purge procedure. Fuel system removal prior to shipment does not require the purge procedure. (1)

While the engine is still in the enclosure, disconnect all fuel manifolds at the package supply interface. WARNING

LUBRICATING OIL, MIL-L-6081, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Liquid Fuel - If present, should be drained into a container or fuel drain tank when the fittings are opened. Any locations such as flow splitter, pressurization valve or flow divider should also be isolated and drained. As an alternative to ventilating, the liquid fuel system can be filled with MIL-L-6081, Grade 1010 slush oil. This alternative is preferred if the engine is to be stored for extended periods before or after service. (b) Gas Fuel - Open the fuel manifold fittings and allow them to ventilate into the enclosure. (2)

Using the Human Machine Interface (HMI), start the enclosure ventilation fan(s).

(3)

Initiate a Dry Crank (no fuel supply) using the HMI and allow the engine to ramp to 2200 rpm HP rotor speed for 10 minutes. This will ventilate any remaining fuel or vapor into the enclosure using compressor discharge air.

(4)

After 10-minute purge, stop dry crank.

(5)


(6)

Complete gas generator removal.




b. Emergency Shutdown or Engine Failure. If the gas generator including fuel system is to be removed from the enclosure in preparation for shipment by ground or air, complete the following fuel system drain and purge procedure. Fuel system removal prior to shipment does not require the purge procedure. (1)

While the engine is still in the enclosure, disconnect all fuel manifolds at the package supply interface as well as at all nozzles or premixers.

(2)

Using the HMI, start the enclosure ventilation fan(s).

(3)

Drain and blow out all fuel lines. WARNING

LUBRICATING OIL, MIL-L-6081, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Liquid fuel - If present, should be drained into an approved container or the fuel drain tank when the fittings are opened. Any locations such as flow splitter, pressurization valve or flow divider should also be isolated and drained. As an alternative to ventilating, the liquid fuel system can be filled with MIL-L-6081, Grade 1010 slush oil. This alternative is preferred if the engine is to be stored for extended periods before or after service. 1

Open the combustor case drain fitting and drain any residual fuel into an approved container or the fuel drain tank. WARNING

WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS. 2

After all fuel is drained, blow out each of the lines, hoses and connections with shop air.

(b) Gas Fuel - Open the fuel manifold fittings and blow out each of the lines, hoses and connections with shop air. (4)


(5)

Reconnect fuel nozzles or premixers.

(6)

Complete gas generator removal.


GEK 105054 Volume II WP 301 00 2.



Title

For LM2500+ Model GK and GV gas generators and Model PK and PV gas turbines: Operation and Maintenance Manual, Volume I GEK 105054 Installation/ Initial Startup and Engine Operation Chapter 7 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Fuel System Replacement WP 101 00 Ignition Exciter Replacement WP 104 00 Gas Generator Speed Sensor Replacement WP 105 00 High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Replacement WP 109 00 Lube System Temperature Sensor Replacement WP 110 00 Accelerometer Replacement WP 111 00 Power Turbine Inlet Pressure (P5.4) Probe Replacement WP 112 00 Gas Generator Outside Piping and Wiring Removal and Installation WP 113 00 Gas Turbine Outside Piping and Wiring Removal and Installation SWP 113 01 Pneumatic Starter (Shrouded/Nonshrouded) Replacement WP 117 00 Hydraulic Starter Replacement SWP 117 01 Hydraulic Pump Replacement WP 120 00 High Pressure Compressor Discharge Temperature (T3) Sensor Replacement WP 123 00 Inlet Duct Replacement WP 204 00 Centerbody Replacement WP 205 00 Maintenance Dolly Usage WP 303 00 Gas Generator/Gas Turbine Shipping WP 502 00 For LM2500+ Model GV gas generator and Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

4.


Part No.

Fixture, Lift-Gas Generator

1C8340G01



Isopropyl Alcohol Lubricating Oil

Fed Spec TT-I-735 MIL-L-23699 or MIL-L-7808 Fed Spec VV-P-236 GE Spec A50TF272 GE Spec A50TF201 or MIL-T-5544

Petrolatum Sealant Thread Lubricant 5.




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 6. Gas Generator Removal. a.

Comply with all instructions contained in WP 002 00. CAUTION GAS GENERATOR SHALL BE HANDLED CAREFULLY. ADEQUATE PRECAUTIONS SHALL BE TAKEN TO PREVENT DAMAGE TO EXTERNAL PIPING AND ELECTRICAL LEADS DURING HANDLING. DO NOT CLIMB OR STEP ONTO ANY PART OF GENERATOR OR PIPING. NOTE Due to configuration differences of OEM-provided gas turbine enclosures, the following procedures may require modification. Refer to packager's manual.

b.

Remove inlet screen and inlet duct per WP 204 00.

c.


d.

Disconnect outside piping and wiring as follows: (1)

Disconnect LM2500+ Models GV or PV gas generator outside piping and wiring from two stage power turbine per GEK 105052.

(2)

Disconnect LM2500+ Model GK gas generator outside piping and wiring from packager supplied power turbine per table 1, WP 113 00, and packager’s manual.

(3)

Disconnect LM2500+ Model PK gas turbine outside piping and wiring per table 1, SWP 113 01, and packager’s manual. WARNING

e.

•


•


Disconnect all fuel, air, lube oil, and instrumentation service connections from gas generator to enclosure. Refer to table 1 and packager’s manual. Drain all residual fluids into approved waste container.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Gas Generator Connections and Hardware Item

Gas Generator D-sump scavenge oil tube D-sump oil supply tube

Item Power turbine Oil tube Oil tube

D-sump vent tube

Air tube

D-sump pressurization tube Balance piston air tube

Air tube

Gas Generator Fuel system components Igniter Speed sensor

Air tube Enclosure Manifold to nozzle and packager connections Ignition exciter Packager lead

P2/T2 sensor

Packager tubing

Lube system RTDs Lube system chip detectors Accelerometer

Packager leads Packager leads

P5.4 Pneumatic starter

Packager tubing Packager connections

Hydraulic starter

Packager connections

Hydraulic pump

Filter in line, filter out line, FMV line Packager connection

T3 sensor P2/T2 and VSV actuators electrical connections Lube and scavenge pump VSV servovalve UV flame sensors T5.4 harness

Packager lead

Packager lead Packager lube oil supply and scavenge hoses Packager leads Packager leads Packager leads

Note N/A Refer to WP 113 00, SWP 113 01 and/or packager’s manual Refer to WP 113 00, SWP 113 01 and/or packager’s manual Refer to WP 113 00, SWP 113 01 and/or packager’s manual Refer to WP 113 00, SWP 113 01 and/or packager’s manual Refer to WP 113 00, SWP 113 01 and/or packager’s manual N/A Refer to WP 101 00 and packager’s manual Refer to WP 104 00 Refer to WP 105 00 and packager’s manual Refer to WP 109 00 and packager’s manual Refer to WP 110 00 Refer to packager's manual Refer to WP 111 00 and packager’s manual Refer to WP 112 00 Refer to WP 117 00 and packager’s manual Refer to SWP 117 01 and packager’s manual Refer to WP 120 00 and packager’s manual Refer to WP 123 00 and packager’s manual Refer to packager’s manual Refer to packager’s manual Refer to packager’s manual Refer to packager’s manual Refer to packager’s manual




For all models, prepare items listed in table 2 for engine shipment. NOTE Use of lift fixture, 1C8340, is dependent on space within enclosure. If space is not sufficient to allow use of lift fixture, 1C8340, attach packager’s lift fixture per packager’s manual.

g.

Disconnect any associated accessories, as required, per packager’s manual.

h.

Install lift fixture, 1C8340 (figure 1), onto gas generator as follows: (1)

Attach enclosure hoist onto lift fixture, 1C8340. Table 2. Shippable Items on Gas Generator Item

P2/T2 sensor T3 sensor CRF accelerometer Optional T3 sensor Igniter Optional igniter Igniter lead(s) UV flame sensor brackets T5.4 probes T5.4 harnesses P5.4 sensor

Action Send with engine Send with engine Send with engine Send with engine Send with engine Send with engine Send with engine Send with engine Send with engine Send with engine Send with engine




Figure 1. Gas Generator with Lift Fixture, 1C8340 (Sheet 1 of 2) 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Gas Generator with Lift Fixture, 1C8340 (Sheet 2 of 2) 9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



ESTABLISH AND RECORD CENTER OF GRAVITY OF LIFT FIXTURE, TO PREVENT FIXTURE PITCHING UPON REMOVAL FROM GAS GENERATOR. (2)

Install lift fixture, 1C8340, aft bracket onto gas generator as follows: CAUTION

SET ASIDE GAS GENERATOR HARDWARE FOR REUSE. DO NOT INTERMIX LIFT FIXTURE HARDWARE WITH GAS GENERATOR HARDWARE. (a) Remove bolt and self-locking nut at 12:00 o’clock position hole of compressor rear frame (CRF) forward flange. (b) Remove seven bolts and self-locking nuts to either side of CRF master hole. (c) Install lift fixture, 1C8340, aft bracket onto aft side of CRF forward flange. (d) Using fifteen 0.3125-18 bolts and nuts, attach lift fixture aft bracket onto CRF forward flange. Tighten bolts to 70-110 lb in. (8.0-12.4 N⋅m) of torque. (3)

Raise lift fixture, 1C8340, to working height.

(4)

Adjust lift fixture trolley for proper center of gravity with gas generator installed.

(5)

Position lift fixture, 1C8340, over gas generator.

(6)

Using two quick-release pins, attach lift fixture forward links to gas generator handling mounts on compressor front frame (CFF).

(7)

Using two quick-release pins, attach lift fixture aft links to aft bracket installed on gas generator. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. i.

Carefully take up slack on enclosure hoist so weight of gas generator is supported by hoist and lift fixture, 1C8340, and tension is relieved from enclosure engine mounts.

j.

Disconnect and remove enclosure engine mounting hardware per packager’s manual.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION VERIFY ALL HOSES, TUBES, AND ELECTRICAL CONNECTIONS AT GAS GENERATOR TO POWER TURBINE MATING FLANGES HAVE BEEN DISCONNECTED, OR DAMAGE TO GAS GENERATOR COULD OCCUR DURING REMOVAL. k.

Separate gas generator from power turbine (PT) as follows: (1)

For LM2500+ Model PK gas turbine, proceed as follows: (a) Provide support for PT forward end during separation. (b) Remove 106 bolts, self-locking nuts, and 73 spacers connecting turbine mid frame (TMF) to power turbine. CAUTION

BE SURE GAS GENERATOR AND POWER TURBINE MAINTAIN CORRECT ALIGNMENT DURING SEPARATION. OTHERWISE, DAMAGE MAY RESULT. (c) Carefully move gas generator forward to clear power turbine forward shaft. Use extreme care to maintain correct alignment of gas generator and power turbine to prevent damage to power turbine shaft, seals, and bearings. (2)

For LM2500+ Model GK gas generator, proceed as follows: (a) Provide support for PT forward end during separation. (b) Remove 106 bolts and self-locking nuts connecting TMF to power turbine. (c) Separate gas generator from power turbine per packager's manual.

(3)

For LM2500+ Model GV gas generator and PV gas turbine, proceed as follows: (a) Provide support for PT forward end during separation. (b) Remove 106 bolts and self-locking nuts connecting TMF to power turbine. (c) Separate gas generator from power turbine per GEK 105052.




ENSURE PROPER ALIGNMENT OF POWER TURBINE AND GAS GENERATOR IS MAINTAINED. BEARINGS AND SEALS COULD BE DAMAGED IF ALIGNMENT IS NOT MAINTAINED DURING SEPARATION. l.

Install protective caps, plugs, or covers. Close all openings to prevent entry of foreign objects and contamination.

m. Move gas generator to enclosure door per packager’s manual. n.

Attach overhead hoist to lift fixture, 1C8340. Take up slack to support lift fixture and gas generator. Remove enclosure hoist from lift fixture. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. NOTE Gas generator can be directly installed into shipping container without use of maintenance dolly, 1C9372, if desired.

o. 7.

Install gas generator into maintenance dolly, 1C9372, per WP 303 00 or shipping container per WP 502 00.

Gas Generator Installation. NOTE

•

Use of lift fixture, 1C8340, is dependent on space within enclosure. If space is not sufficient to allow use of lift fixture, 1C8340, attach packager’s lift fixture per packager’s manual.

•

Gas generator can be directly installed into enclosure without use of maintenance dolly, 1C9372, if desired.

a.

Remove gas generator from shipping container per WP 502 00, or maintenance dolly, 1C9372, per WP 303 00.

b.

Carefully move gas generator to enclosure door. Connect enclosure hoist to lift fixture, 1C8340, per packager’s manual. Disconnect overhead hoist from lift fixture.




c.

•

If installing LM2500+ Model PK gas generator onto a six stage power turbine, use step c.

•

If installing LM2500+ Model GK onto a packager supplied power turbine, consult packager’s manual and proceed to step d.

•

If installing onto LM2500+ Model GV or PV onto a two stage power turbine, consult GEK 105052, and proceed to step d.

Align and install LM2500+ Model PK gas generator onto power turbine as follows: CAUTION ENSURE PROPER ALIGNMENT OF POWER TURBINE AND GAS GENERATOR IS MAINTAINED. BEARINGS AND SEALS COULD BE DAMAGED IF ALIGNMENT IS NOT MAINTAINED DURING SEPARATION. (1)

Coat No. 6 roller bearings with petrolatum and press to outward most positions. WARNING


Using isopropyl alcohol, clean TMF aft flange and power turbine forward flange.

(3)

Lightly coat TMF aft flange mating surfaces with sealant. WARNING

WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY. CAUTION USE EXTREME CARE TO MAINTAIN CORRECT ALIGNMENT OF GAS GENERATOR AND POWER TURBINE, TO PREVENT DAMAGE TO POWER TURBINE SHAFT, SEALS, AND BEARINGS. (4)

Carefully move gas generator aft.

(5)

Coat 106 bolt threads, contact faces, and nut contact faces with thread lubricant.




Spacers are located on bolts installed in boltholes 1 through 7, 10 through 16, 19 through 22, 24, 26, 30 through 35, 38 through 44, 47 through 51, 55, 59 through 63, 66 through 71, 74, through 80, 84, 86, 88 through 90, 96 through 100, and 103 through 108. (6)

Install 106 bolts through power turbine forward flange and TMF aft flange using 73 spacers, as required, per figure 2 and table 2.

(7)

Install self-locking nuts onto bolts. Tighten bolts to 190-230 lb in. (21.5-29.9 N⋅m) of torque.

d.

Install enclosure mounting hardware per packager’s manual.

e.

Remove lift fixture, 1C8340 (figure 1), from gas generator as follows: (1)

Using two quick-release pins, attach lift fixture forward links to gas generator forward handling mounts on CFF.

(2)

Using two quick-release pins, attach lift fixture aft links to aft bracket installed on gas generator.

(3)

Remove 15 bolts and self-locking nuts securing CRF forward flange to lift fixture, 1C8340, aft bracket.

(4)

Remove lift fixture, 1C8340, aft bracket from CRF forward flange. CAUTION

(5)

•

INSTALL PRIME GAS GENERATOR HARDWARE. DO NOT INTERMIX FIXTURE HARDWARE WITH GAS GENERATOR HARDWARE OR DAMAGE TO GAS GENERATOR WILL OCCUR.

•

INSTALL THREE LONGER BOLTS IN BOLTHOLES USED TO SECURE SUMP SUPPORT BRACKET. OTHERWISE, DAMAGE MAY RESULT.

Install 15 prime bolts and nuts through high pressure compressor (HPC) rear stator case rear flange. Tighten bolts to 209-231 lb in. (23.6-26.09 N⋅m) of torque. WARNING

ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. f.

Connect gas generator outside piping and wiring as follows: (1)

Connect LM2500+ Model PK gas generator and power turbine outside piping and wiring per table 1, SWP 113 01, and packager’s manual.




(2)

Connect LM2500+ Model GK gas generator and power turbine outside piping and wiring per table 1, WP 113 00, and packager’s manual.

(3)

Connect LM2500+ Model GV and Model PV gas generator and power turbine outside piping and wiring per GEK 105052.

g.

Connect all fuel, air, lube oil, and instrumentation service connections from gas generator to enclosure. Refer to table 1 and packager’s manual.

h.

Connect any associated accessories, as required, per packager’s manual.

i.


j.

Inspect gas generator air inlet duct area with strong light for foreign objects. Pay special attention to locations behind inlet guide vanes (IGV’s) and stage 1 blades and vanes at 6:00 o’clock position in frame and at 12:00 o’clock position on hub.

k.

Install inlet duct per WP 204 00.

l.

Perform installation checkout per packager’s manual.

m. Perform functional and operational tests per GEK 105054, Chapter 7.




Figure 2. Power Turbine/TMF Flange - PK Model 16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Power Turbine/TMF Flange Hardware Installation - PK Model Bolthole No.

Bolthead Direction

Spacer

Bolthole No.

Bolthead Direction

Spacer

NOTE All spacers are installed under boltheads. 1-4

FWD

X

52-54

FWD

5

AFT

X

55

FWD

6-7

FWD

X

56-58

FWD

8-9

FWD

59-62

FWD

X

10-16

FWD

63

AFT

X

17-18

FWD

64-65

FWD

19-20

FWD

X

66-71

FWD

21

AFT

X

72-73

FWD

22

FWD

X

74-80

FWD

23

FWD

81

AFT

24

FWD

82

Not Used

25

FWD

83

AFT

26

FWD

84

FWD

27

AFT

85

FWD

28

Not Used

86

FWD

29

AFT

87

FWD

30-35

FWD

88-90

FWD

36-37

FWD

91-95

FWD

38

FWD

X

96

AFT

X

39

AFT

X

97-100

FWD

X

40-44

FWD

X

101-102

FWD

45-46

FWD

103-108

FWD

47-51

FWD

X

X X

X

X

X X

X X X

X

X




WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE ASSEMBLY REPLACEMENT (LEVEL 1 AND 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS PK AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Power Turbine Installation................................................................................................. Power Turbine Removal......................................................................................................

7 3


GEK 105054 Volume II WP 302 00 1.


Introduction. This work package contains instructions for removal and installation of a LM2500+ Model PK power turbine. If removing and installing a LM2500+ Model PV two stage power turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown, for further instructions.

2.


Title For LM2500+ Model PK power turbine: Operation and Maintenance Manual, Volume I Installation/ Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Accelerometer Replacement Power Turbine Forward Adapter Replacement Gas Generator Assembly Replacement Maintenance Dolly Usage Power Turbine Shipping For LM2500+ Model PV gas turbine: Operation and Maintenance Manual Illustrated Parts Breakdown 3.

4.

5.

GEK 105054 Chapter 7 GEK 105054 WP 002 00 WP 111 00 WP 220 00 WP 301 00 WP 303 00 WP 503 00 GEK 105052 GEK 105053


Part No.

Fixture, Lift-Power Turbine Mount Set, Ground Handling-Power Turbine Container, Shipping-Power Turbine

1C6955G03 1C8321G01 106C7157G01



Isopropyl Alcohol Thread Lubricant

Fed Spec TT-I-735 GE Spec A50TF201 or MIL-T-5544





Power Turbine Removal. a.

Comply with all instructions contained in WP 002 00. NOTE Due to configuration differences of gas turbine enclosures, following procedure may require modification. Refer to packager’s manual.

b.

Remove gas generator from enclosure per WP 301 00.

c.

Secure high speed coupling shaft per packager’s manual. CAUTION ENSURE POWER TURBINE FORWARD ADAPTER IS MATCHMARKED TO HIGH SPEED COUPLING SHAFT PRIOR TO REMOVING, TO ENSURE PROPER ALIGNMENT AT INSTALLATION.

d.

Disconnect high speed coupling shaft from power turbine forward adapter per packager’s manual.

e.

Disconnect power turbine from exhaust system components per packager’s manual.

f.

Install power turbine ground handling mount fixtures, 1C8321 (figure 1), onto power turbine as follows: CAUTION DO NOT TURN BODY-BOUND BOLTS DURING REMOVAL, OR DAMAGE TO POWER TURBINE STATOR CASING MAY OCCUR. (1)

Remove nine bolts, in boltholes 1 through 9, on horizontal split flange of power turbine stator case. Retain engine hardware for reinstallation.

(2)

Remove four bolts, washers, and nuts, on power turbine forward vertical flange, in boltholes immediately underneath horizontal split-line. Retain engine hardware for reinstallation. NOTE

Ground handling mount fixtures, 1C8321, are marked as to which side of power turbine they are to be installed on. Ensure fixtures are installed onto lower side of horizontal split-line flange. (3)

Using slave hardware, attach ground handling mount fixture, 1C8321, onto power turbine. Tighten bolts to 70-110 lb in. (8.0-12.4 N⋅m) of torque.




Figure 1. Power Turbine Ground Handling Mounts, 1C8321 g.

Remove packager connections to power turbine speed transducer leads per packager’s manual.

h.

Remove turbine rear frame (TRF) accelerometer and cable per WP 111 00. NOTE Use of lift fixture, 1C6955, is dependent on space within enclosure. If space is not sufficient to allow use of lift fixture, 1C6955, attach packager’s lift fixture per packager’s manual.

i.

Install lift fixture, 1C6955, onto power turbine (figure 2) as follows: (1)

Attach hoist to lift fixture, 1C6955, by engaging hoist hook in trolley clevis of lift fixture.

(2)

Position lift fixture, 1C6955, over power turbine assembly.

(3)

Lower lift fixture, 1C6955, until lift pins in legs of forward yoke align with aft holes in ground handling mount fixtures, 1C8321, on power turbine.




Figure 2. Power Turbine and Lift Fixture, 1C6955 (4)

Raise latch and slide lift pin into ground handling mount fixture, 1C8321, on both sides of power turbine.

(5)

Ensure spring stop returns latch to the down position to retain pin in the engaged position.

(6)

Using ball lock pins, attach aft brackets to ground handling mounts of TRF. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. k.

Carefully take up slack on enclosure hoist so weight of power turbine is supported by hoist and lift fixture, 1C6955, and tension is relieved from enclosure power turbine mounts.

l.

Disconnect and remove enclosure power turbine mounting hardware per packager’s manual.

m. Carefully move power turbine to enclosure door per packager’s manual.




n.

Attach overhead hoist to lift fixture, 1C6955. Take up slack to support lift fixture and power turbine.

o.

Remove enclosure hoist from lift fixture, 1C6955.

p.

Using overhead hoist and lift fixture, 1C6955, move power turbine out of enclosure.

q.

If required, remove forward adapter from power turbine per WP 220 00. NOTE Power turbine can be directly installed into shipping container without use of maintenance dolly, 1C9372, if desired.

r.

Handle power turbine as follows: (1)

If applicable, install power turbine onto maintenance dolly, 1C9372, per WP 303 00.

(2)

If applicable, prepare power turbine for installation into shipping container, 106C7157, as follows: (a) Attach overhead hoist and nylon sling to shipping container forward strongback. (b) Configure shipping ring onto shipping container forward strongback for use with thick flange power turbine. (c) Using 14 capscrews, washers, and nuts, install shipping ring onto shipping container forward strongback. Tighten capscrews to 480-570 lb in. (54.3-64.4 N⋅m) of torque. (d) Align shipping container forward strongback with power turbine rotor. CAUTION

ENSURE PLUG OF SHIPPING CONTAINER FORWARD STRONGBACK SLIDES INTO FORWARD SHAFT OF POWER TURBINE ROTOR. (e) Carefully slide shipping container forward strongback onto power turbine rotor forward shaft.




(f) Using hoist, nylon sling, and shipping container forward strongback, carefully raise power turbine rotor until boltholes in shipping container forward strongback align with power turbine forward flange boltholes. NOTE Install bolts equally spaced around power turbine forward flange. (g) Using 54 bolts and nuts, attach shipping container forward strongback to power turbine forward flange. Tighten bolts to 160-210 lb in. (18.1-27.3 N⋅m) of torque. (h) Install power turbine into shipping container per WP 503 00. 7.

Power Turbine Installation. NOTE Power turbine can be removed directly from shipping container without use of maintenance dolly, 1C9372, if desired. a.

Remove power turbine from maintenance dolly, 1C9372, per WP 303 00 or shipping container per WP 503 00.

b.

If required, install forward adapter onto power turbine per WP 220 00. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA.

c.

Using isopropyl alcohol, clean power turbine forward flange. NOTE Use of lift fixture, 1C6955, is dependent on space within enclosure. If space is not sufficient to allow use of lift fixture, 1C6955, attach packager’s lift fixture per packager’s manual.

d.

Carefully move power turbine to enclosure door. Connect enclosure hoist to lift fixture, 1C6955, per packager’s manual. Disconnect overhead hoist from lift fixture.

e.

Move power turbine into enclosure per packager’s manual.




f.

Align matchmarks and install power turbine forward adapter onto high speed coupling shaft per packager’s manual.

g.

Install and connect enclosure power turbine mounting hardware per packager’s manual.

h.

Install packager supplied power turbine speed transducer leads per packager's manual.

i.

Install TRF accelerometer per WP 111 00.

j.

Remove lift fixture, 1C6955 (figure 2), from power turbine as follows:

k.

(1)

Remove ball lock pins that secure power turbine lift fixture, 1C6955, aft mounting brackets to TRF ground handling mounts.

(2)

Raise latch and move lift pin to disengage from ground handling mount fixtures, 1C8321, on both sides of power turbine.

(3)

Ensure spring stop returns latch to the down position to retain pin in the disengaged position.

(4)

Using hoist, lift and remove lift fixture, 1C6955, from power turbine.

Remove ground handling mount fixtures, 1C8321 (figure 1), as follows: (1)

Remove five slave bolts, in boltholes 3 through 5, and 7 and 8, on horizontal split flange of power turbine stator case.

(2)

Lightly coat engine hardware threads and contact faces with thread lubricant. CAUTION

DO NOT TURN BODY-BOUND BOLTS DURING INSTALLATION, OR DAMAGE TO POWER TURBINE STATOR CASING MAY OCCUR. (3)

Reinstall and tighten bolts into power turbine stator case horizontal split flange per table 1.

(4)

Reinstall four bolts, washers, and nuts on power turbine forward vertical flange, in boltholes immediately underneath both horizontal split-line flanges. Tighten bolts to 162-178 lb in. (18.4-20.1 N⋅m) of torque.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Horizontal Split-Line Bolt Placement Bolt Size

Bolt Type

Bolthole Location

Final Torque

0.3125-24

Machine

1

276-304 lb in. (31.1-34.3 N⋅m)

0.3125-24

Body-Bound

2

162-178 lb in. (18.4-19.6 N⋅m)

0.3125-24

Machine

3 through 9

162-178 lb in. (18.4-19.6 N⋅m)

l.

Connect power turbine to exhaust system components per packager’s manual.

m. Remove hardware used to secure high speed coupling shaft per packager’s manual. CAUTION ENSURE GAS GENERATOR AFT FLANGE IS CLEAN AND FREE FROM DEFECTS PRIOR TO INSTALLING ONTO POWER TURBINE. n.

Install gas generator into enclosure per WP 301 00.

o.

Perform power turbine installation checkout per packager’s manual.

p.

Perform power turbine functional and operational checks per GEK 105054, Chapter 7.




WORK PACKAGE

TECHNICAL PROCEDURES MAINTENANCE DOLLY USAGE (LEVEL 1 AND 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, AND PK


Change No.

Page No.

Change No.

Page No.

Change No.


Page

Gas Generator Installation Into Maintenance Dolly......................................................... Gas Generator Removal From Maintenance Dolly. .......................................................... Gas Turbine Installation Into Maintenance Dolly. ........................................................... Gas Turbine Removal From Maintenance Dolly. .............................................................. Maintenance Dolly Configuration. ..................................................................................... Power Turbine Installation Into Maintenance Dolly. ....................................................... Power Turbine Removal From Maintenance Dolly. ..........................................................

18 23 14 17 3 25 28


GEK 105054 Volume II WP 303 00 1.


Introduction. This work package provides instructions for installing and removing a LM2500+ Models GK and GV gas generator, Model PK gas turbine, or GE supplied six stage power turbine from the maintenance dolly. For LM2500+ Model PV gas turbine or two stage power turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown. If maintenance dolly requires towing, attach tow bar, 9448M49G01, and tow to location.

2.


Title

For LM2500+ Models GK and GV gas generators, Model PK gas turbine, and GE supplied six stage power turbines: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Gas Generator Outside Piping and Wiring Removal and Installation WP 113 00 Gas Turbine Outside Piping and Wiring Removal and Installation SWP 113 01 Power Turbine Forward Adapter Replacement WP 220 00 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Power Turbine Assembly Replacement WP 302 00 Gas Generator/Gas Turbine Shipping WP 502 00 Power Turbine Shipping WP 503 00 For LM2500+ Model PV gas turbine or two stage power turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


Part No.

Fixture, Lift-Power Turbine Assembly Adapter Assembly, Maintenance Dolly Mount Set, Ground Handling-Power Turbine Jack Assembly, Support Compressor Rear Frame Fixture, Lift-Gas Generator Fixture, Lift-Gas Turbine Fixture, Aft Lift and Turn-Power Turbine Frame Assembly, Maintenance Dolly Shipping Container-Power Turbine Bar, Tow (for use with 1C9372) Sling, Nylon (1,000 lb [453 kg] minimum rating)

1C6955G03 1C8302G05 1C8321G01 1C8333G01 1C8340G01 1C8341G01 1C8342G01 1C9372G05 106C7157G01 9448M49G01 Local Purchase




Consumable Material. Thread Lubricant

5.


6.

Maintenance Dolly Configuration. a.


Configure adapter assembly, 1C8302, onto maintenance dolly, 1C9372 (figure 1), per table 1 and as follows: (1)

When configuring adapter assembly, 1C8302, onto maintenance dolly, 1C9372, install support posts loosely. Final tighten support posts only after engine is fully installed and before removing lift fixture.

(2)

Install compressor front frame (CFF) support posts (2, figure 2) onto maintenance dolly (1) as follows: (a) Place two CFF support posts (2) onto maintenance dolly (1) so forward edge of posts are 19.0 inches (48.2 cm) from forward reference point of maintenance dolly (figure 1). (b) Using eight capscrews (3, figure 2), washers (4), and nuts (5), secure two CFF support posts (2) to maintenance dolly (1).

(3)

Install two high pressure compressor (HPC) support posts (2, figure 3) onto maintenance dolly (1) as follows: (a) Place two HPC support posts (2) onto maintenance dolly (1) so forward edge of posts are 76.6 inches (194.5 cm) from forward reference point of maintenance dolly (figure 1). (b) Using eight capscrews (3, figure 3), washers (4), and nuts (5), secure two HPC support posts (2) to maintenance dolly (1).

(4)

Install compressor rear frame (CRF) support jack (9, figure 4), onto maintenance dolly (1) as follows: (a) Install aft middle cross bar, 1C9372P23, onto maintenance dolly (1) at approximately 123.0 inches (309.9 mm) from forward reference point of maintenance dolly (figure 1). (b) Place CRF support jack, 1C8333 (9, figure 4), onto aft middle crosspiece (figure 1).




Install pedestal only if using support posts set to high setting. (c) Using four screws (3, figure 4), washers (4), and nuts (5), secure pedestal (2) onto maintenance dolly (1). (d) Using four screws (6), washers (7), and nuts (8), secure CRF support jack (9) to pedestal (2). Table 1. Maintenance Dolly Configuration

CFF Supports

HPC Supports

CRF Support Jack

Gas Generator Transfer

X

X

X

Gas Turbine Transfer

X

Maintenance Task

Power Turbine Supports

X

Power Turbine Transfer

X

High Pressure Turbine Maintenance

X

X

X

Combustor Maintenance

X

X

X

Gas Generator HPC Maintenance

X

X

Gas Turbine HPC Maintenance

X

X

Power Turbine Maintenance X

Gas Turbine External Maintenance

X

X

X

X X

Gas Generator External Maintenance

TRF Supports

X

X

X




Power turbine support posts are required when installing power turbine only into maintenance dolly. (5)

Install two power turbine support posts (figure 5) onto maintenance dolly, 1C9372, as follows: (a) Place two power turbine support posts (2, figure 6) onto maintenance dolly (1) so forward edge of posts are 139.7 inches (354.8 cm) from forward reference point of maintenance dolly (figure 5). (b) Using eight capscrews (3, figure 6), washers (4), and nuts (5), secure two power turbine support posts (2) to maintenance dolly (1).

(6)

Install two turbine rear frame (TRF) support posts (2, figure 7) onto maintenance dolly, 1C9372, as follows: (a) Place two TRF support posts (2) onto maintenance dolly (1) so forward edge of posts are 176.9 inches (449.3 cm) from forward reference point of maintenance dolly (figure 1). (b) Using eight capscrews (3, figure 7), washers (4), and nuts (5), secure two TRF support posts (2) to maintenance dolly (1).




Figure 1. Maintenance Dolly, 1C9372, and Adapter Assembly, 1C8302 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



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



Figure 3. HPC Support Posts 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 4. CRF Support Jack, 1C8333 9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 5. Power Turbine Installation onto Maintenance Dolly, 1C9372 10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 6. Power Turbine Support Posts 11 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Adjust adapter assembly, 1C8302, support post heights as follows: NOTE

•

Lower height setting of adapter assembly, 1C8302, support posts is 64.9 inches (164.8 cm). Upper height setting of support posts is 74.9 inches (190.2 cm).

•

Use step (1) for setting adapter assembly, 1C8302, support posts to high setting. Use step (2) for setting adapter support posts to low setting.

•

Pedestal is required on CRF support jack, 1C8333, when support posts are set to high setting.

(1)

If applicable, set support posts for high setting as follows: (a) Pull quick-release pin (6, figures 2, 3, 6, and 7). (b) Raise adjustment shaft (9) until lower quick-release pinhole in adjustment shaft aligns with post hole. (c) Insert quick-release pin (6) through hole in post and adjustment shaft (9). (d) Thread adjustment nut (7) down adjustment shaft (9) until nut rests against bearing washer (8).

(2)

If applicable, set support posts for low setting as follows: (a) Thread adjustment nut (7) up adjustment shaft (9) until nut rests against support block (10). (b) Pull quick-release pin (6). (c) Lower adjustment shaft (9) until upper quick-release pinhole in adjustment shaft aligns with post hole.




Figure 7. TRF Support Posts 13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (d) Insert quick-release pin (6) through hole in post and adjustment shaft (9). (e) Thread adjustment nut (7) down adjustment shaft (9) until nut rests against bearing washer (8).

7.

Gas Turbine Installation Into Maintenance Dolly. a.

Remove gas turbine from enclosure per WP 300 00, or from shipping container, 106C7157, per WP 502 00.

b.

Install support posts required for operation. Refer to table 1.

c.

Prepare support posts for gas turbine installation as follows: (1)

Remove two safety pin fasteners (12, figure 2) from pins (13) in support plates (11) on CFF support posts (2) and remove pins (13).

(2)

Remove three quick release pins (12, figure 7) from support plates (11) from TRF support posts (2).

(3)

If required per table 1, remove channel (12, figure 3) from HPC support post (2) as follows: (a) Remove four quick-release pins (11) from channel (12) and support plates (13). WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (b) Using hoist and nylon sling, lift and remove channel (12) from HPC support posts (2). Set channel aside. CAUTION ALL ADAPTER ASSEMBLY, 1C8302, SUPPORT POSTS SHALL BE AT SAME SETTING, EITHER HIGH OR LOW, OR GAS TURBINE SHALL BE UNABLE TO BE INSTALLED ONTO MAINTENANCE DOLLY, 1C9372. (4)

Set all support posts to upper or lower setting, as required, per paragraph 6, step b.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. d.

Using hoist and lift fixture, 1C8341, align gas turbine over maintenance dolly, 1C9372.

e.

Carefully lower gas turbine into position between support posts. WARNING WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY.

f.

g.

h.

Install gas turbine into maintenance dolly, 1C9372, and adapter assembly, 1C8302, as follows: (1)

Install two pins (13, figure 2) through support plates (11) into CFF lower ground handling mounts. Install safety pin fasteners (12) through pins (13).

(2)

Install three pins (12, figure 7) through support plate (11) into TRF ground handling mounts.

(3)

Final tighten all support posts onto maintenance dolly (1). Torque to 420-510 lb in. (47.5-57.6 Nxm) of torque.

Remove lift fixture, 1C8341 (figure 8), from gas turbine as follows: (1)

Remove two quick-release pins that attach lift fixture forward links to gas turbine forward handling mounts on CFF.

(2)

Remove two quick-release pins that attach lift fixture aft links to gas turbine aft handling mounts on TRF.

(3)

Using hoist, raise lift fixture, 1C8341, away from gas turbine.

If required per table 1, install channel (12, figure 3) onto HPC support posts (2) as follows: (1)

Remove quick-release pins (6) from HPC support posts (2).

(2)

Using adjustment nut (7), raise support blocks (10) so engine mount plate (14) will clear gas turbine when reinstalled.







8.

(3)

Using hoist and nylon sling, lift channel (12) and engine mount plate (14), and install onto HPC support posts (2).

(4)

Install four quick-release pins (11) through channel (12) and support plates (13).

(5)

Remove bolts and nuts in forward compressor case aft flange that match engine mount plate (14) boltholes. Retain engine flange hardware for reinstallation.

(6)

Using adjustment nuts (7), lower channel (12) so that engine mount plate (14) boltholes align with forward compressor case aft flange boltholes.

(7)

Using 16 capscrews (15) and nuts (16), secure engine mount plate (14) onto forward compressor case aft flange. Tighten capscrews to 160-210 lb in. (18.0-23.7 N⋅m) of torque.

(8)

Install quick-release pins (6) into HPC support posts (2).

Gas Turbine Removal From Maintenance Dolly. a.


b.

If installed, remove channel (12, figure 3) from gas turbine and compressor support posts as follows: (1)

Remove capscrews (15) and nuts (16) that secure engine mount plate (14) onto forward compressor case aft flange.

(2)

Remove four quick-release pins (11) from channel bar (12) and support plates (13). WARNING


Using hoist and nylon sling, lift and remove channel bar (12) from compressor support posts. Set channel bar aside.

(4)

Reinstall engine nuts and bolts. Tighten bolts to 190-230 lb in. (21.5-29.9 N⋅m) of torque.


GEK 105054 Volume II WP 303 00 c.

d.


Install lift fixture, 1C8341 (figure 8), onto gas turbine as follows: (1)

Attach hoist onto lift fixture, 1C8341.

(2)

Raise lift fixture, 1C8341, and align over gas turbine.

(3)

Using two quick-release pins, attach lift fixture forward links to gas turbine forward handling mounts on CFF.

(4)

Using two quick-release pins, attach lift fixture aft links to gas turbine aft handling mounts on TRF.

(5)

Using hoist, take up slack so weight of gas turbine is transferred to lift fixture, 1C8341.

Remove pins that secure gas turbine to support posts as follows: (1)

Remove two safety pin fasteners (12) and remove two pins (13, figure 2) that secure CFF support posts (2) to CFF.

(2)

Remove three pins (12, figure 7) that secure TRF support posts (2) to TRF. WARNING


9.

e.

Lift gas turbine from maintenance dolly, 1C9372.

f.

Install gas turbine into enclosure per WP 300 00 or into shipping container, 106C7157, per WP 502 00.

Gas Generator Installation Into Maintenance Dolly. a.

Remove gas generator from enclosure per WP 301 00, or from shipping container per WP 502 00.

b.





Prepare support posts for gas generator installation as follows: (1)

Remove two safety pin fasteners (12) and remove two pins (13, figure 2) from support plates (11) on CFF support posts (2).

(2)

Remove channel (12, figure 3) from HPC support post (2) as follows: (a) Remove four quick-release pins (11) from channel (12) and support plates (13). WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (b) Using hoist and nylon sling, lift and remove channel (12) from HPC support posts (2). Set channel aside. CAUTION ALL ADAPTER ASSEMBLY, 1C8302, SUPPORT POSTS SHALL BE AT SAME SETTING, EITHER HIGH OR LOW, OR GAS TURBINE SHALL BE UNABLE TO BE INSTALLED ONTO MAINTENANCE DOLLY, 1C9372. (3)

Set all support posts to upper or lower setting, as required, per paragraph 6, step b. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. d.

Using hoist and lift fixture, 1C8340, align gas generator over maintenance dolly, 1C9372.

e.

Remove any external piping and wiring at CRF 6:00 o’clock position per WP 113 00 or SWP 113 01. WARNING WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY.

f.

Carefully lower gas generator into position between support posts.


GEK 105054 Volume II WP 303 00 g.


Install gas generator into maintenance dolly, 1C9372, and adapter assembly, 1C8302, as follows: (1)

Install two pins (13, figure 2) through support plate (11) into CFF lower ground handling mounts. Install safety pin fasteners (12) through pins (13). WARNING

SERIOUS INJURY CAN OCCUR WHEN APPLYING HYDRAULIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS. (2) h.

Raise CRF support jack, 1C8333 (9, figure 4), until it engages CRF.

Remove lift fixture, 1C8340 (figure 9), from gas generator as follows: (1)

Remove two quick-release pins, attaching lift fixture forward links to gas generator forward handling mounts on CFF.

(2)

Remove two quick-release pins, attaching lift fixture aft links to aft bracket installed on gas generator.

(3)

Remove 15 bolts and self-locking nuts that secure CRF forward flange to lift fixture, 1C8340, aft bracket.

(4)

Remove lift fixture, 1C8340, aft bracket from CRF forward flange. CAUTION

(5)

i.

•

DO NOT INTERMIX FIXTURE HARDWARE WITH GAS GENERATOR HARDWARE.

•

INSTALL THREE LONGER BOLTS IN BOLTHOLES USED TO SECURE SUMP SUPPORT BRACKET.

Lubricate with thread lubricant and install 15 gas generator bolts and nuts through HPC rear stator case rear flange. Tighten bolts to 209-231 lb in. (23.6-26.0 Nxm) of torque.

Install channel (12, figure 3) onto HPC support posts as follows: (1)

Remove quick-release pins (6) from HPC support posts (2).

(2)

Using adjustment nut (7), raise support blocks (10) so engine mount plate (14) will clear gas generator when reinstalled.




Figure 9. Gas Generator Lift Fixture, 1C8340 (Sheet 1 of 2) 21 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 9. Gas Generator Lift Fixture, 1C8340 (Sheet 2 of 2) 22 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



j.

(3)

Using hoist and nylon sling, lift channel (12) and engine mount plate (14), and install onto HPC support posts (2).

(4)

Install four quick-release pins (11) through channel (12) and support plates (13).

(5)

Remove bolts and nuts in forward compressor case aft flange that match engine mount plate (14) boltholes. Retain engine flange hardware for reinstallation.

(6)

Using adjustment nuts (7), lower channel (12) so that engine mount plate (14) boltholes align with forward compressor case aft flange boltholes.

(7)

Using capscrews (15) and nuts (16), secure engine mount plate (14) onto forward compressor case aft flange. Tighten capscrews to 160-210 lb in. (18.0-23.7 N⋅m) of torque.

(8)

Install quick-release pins (6) into HPC support posts (2).

Final tighten support posts onto maintenance dolly (1) to 420-510 lb in. (47.5-57.6 Nxm) of torque.

10. Gas Generator Removal From Maintenance Dolly. a.


b.

Remove channel (12, figure 3) from gas generator and compressor support posts as follows: (1)

Remove 16 capscrews (15) and nuts (16) that secure engine mount plate (14) onto forward compressor case aft flange.

(2)

Remove four quick-release pins (11) from channel (12) and support plates (13). WARNING


Using hoist and nylon sling, lift and remove channel (12) from HPC support posts (2). Set channel aside.


GEK 105054 Volume II WP 303 00 (4) c.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Lubricate with thread lubricant and reinstall engine nuts and bolts. Tighten bolts to 190-230 lb in. (21.5-29.9 N⋅m) of torque.

Install lift fixture, 1C8340 (figure 9), onto gas generator as follows: (1)

Install lift fixture, 1C8340, aft bracket onto gas generator as follows: CAUTION

SET ASIDE GAS GENERATOR HARDWARE FOR REUSE. DO NOT INTERMIX FIXTURE HARDWARE WITH GAS GENERATOR HARDWARE. (a) Remove bolt and self-locking nut in 12:00 o’clock position hole of CRF forward flange. (b) Remove seven bolts and self-locking nuts to either side of CRF 12:00 o’clock position hole. (c) Install lift fixture, 1C8340, aft bracket onto aft side of CRF forward flange. (d) Using fifteen 0.3125-18 bolts and nuts, attach lift fixture aft bracket onto CRF forward flange. Tighten bolts to 70-110 lb in. (8.0-12.4 N⋅m) of torque. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (2)


(3)


(4)


(5)

Using two quick-release pins, attach lift fixture forward links to gas generator forward handling mounts on CFF.

(6)

Using two quick-release pins, attach lift fixture aft links to aft bracket installed on gas generator.

(7)

Using hoist, take up slack so weight of gas generator is transferred to lift fixture, 1C8340. Adjust lift fixture trolley as necessary.




Remove two safety pin fasteners (12, figure 2) and remove two pins (13) that secure CFF support posts (2) to CFF. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY.

e.

Lift gas generator from maintenance dolly, 1C9372.

f.

Install any removed external piping and wiring at CRF 6:00 o’clock position per WP 113 00 or SWP 113 01.

g.

Install gas generator into enclosure per WP 301 00 or into shipping container, 106C7157, per WP 502 00.

11. Power Turbine Installation Into Maintenance Dolly. a.

Remove power turbine from enclosure per WP 302 00 or from shipping container per WP 503 00.

b.


c.

Prepare support posts for power turbine installation as follows: (1)

Remove two pins (12, figure 6) from support plates (11) on power turbine support posts (2).

(2)

Remove three pins (12, figure 7) from support plates (11) on TRF support posts (2). CAUTION

ALL ADAPTER ASSEMBLY, 1C8302, SUPPORT POSTS SHALL BE AT SAME SETTING, EITHER HIGH OR LOW, OR POWER TURBINE SHALL BE UNABLE TO BE INSTALLED ONTO MAINTENANCE DOLLY, 1C9372. d.

Adjust adapter assembly, 1C8302, support post heights per paragraph 6, step b.

e.

Using hoist(s) and lift fixture, 1C8340, align power turbine over maintenance dolly, 1C9372.




WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY. f.

Carefully lower power turbine into position between support posts.

g.

Install power turbine onto maintenance dolly, 1C9372, as follows: (1)

Install two pins (12, figure 6) through support plates (11) on power turbine support posts (2). Pins shall engage in ground handling mount fixtures, 1C8321, forward holes.

(2)

Install three pins (12, figure 7) through support plates (11) on TRF support posts (2). Pins shall engage in TRF engine mounts. NOTE

If lift fixture, 1C6955, is installed, remove per step (1). If aft lift and turn fixture, 1C8342, is installed, remove per step (2). h.

Remove lift fixture as follows: (1)

Remove lift fixture, 1C6955 (figure 10), from power turbine as follows: (a) Remove ball lock pins that secure power turbine lift fixture, 1C6955, aft mounting brackets to TRF ground handling mounts. (b) Raise latch to allow pin to be moved in slot to disengage lift pins from ground handling mount fixtures, 1C8321. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (d) Using hoist, lift and remove lift fixture, 1C6955, from power turbine. (2)

Remove aft lift and turn fixture, 1C8342 (figure 11), from power turbine as follows: (a) Remove 32 bolts, washers, and nuts that secure aft lift and turn fixture, 1C8342, to TRF aft flange. (b) Raise and move aft lift and turn fixture, 1C8342, away from power turbine.




Figure 10. Power Turbine Lift Fixture, 1C6955

Figure 11. Aft Lift and Turn Fixture, 1C8342 27 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



IF POWER TURBINE REQUIRES TRANSPORTATION TO INSTALLATION SITE, LEAVE SHIPPING CONTAINER FORWARD STRONGBACK INSTALLED ON POWER TURBINE UNTIL AT INSTALLATION SITE. i.

If power turbine has been removed from shipping container, 106C7157, remove shipping container hardware as follows: (1)

Attach overhead hoist and nylon sling to shipping container forward strongback. Take up slack.

(2)

Remove 54 bolts and nuts that attach shipping container forward strongback to power turbine forward flange. WARNING


Using hoist, nylon sling, and shipping container forward strongback, carefully lower power turbine rotor so it rests on stator case.

(4)

Carefully pull shipping container forward strongback off power turbine forward shaft.

(5)

Install shipping container forward strongback into shipping container, 106C7157, per WP 503 00.

12. Power Turbine Removal From Maintenance Dolly. a.

Comply with all instructions contained in WP 002 00. CAUTION IF POWER TURBINE REQUIRES TRANSPORTATION TO SHIPPING CONTAINER SITE, INSTALL SHIPPING CONTAINER FORWARD STRONGBACK ONTO POWER TURBINE FORWARD FLANGE PRIOR TO MOVING TO SHIPPING CONTAINER SITE.

b.

If power turbine is to be installed into shipping container, install container hardware as follows: (1)

Attach overhead hoist and nylon sling to shipping container forward strongback.

(2)

Configure shipping ring onto shipping container forward strongback for use with thick flange power turbine.




Using 14 capscrews, washers, and nuts, install shipping ring onto shipping container forward strongback. Tighten capscrews to 480-570 lb in. (54.3-64.4 N⋅m) of torque.

(4)

Align shipping container forward strongback with power turbine rotor. CAUTION

ENSURE PLUG OF SHIPPING CONTAINER FORWARD STRONGBACK SLIDES INTO FORWARD SHAFT OF POWER TURBINE ROTOR. (5)

Carefully slide shipping container forward strongback onto power turbine rotor forward shaft.

(6)

Using hoist, nylon sling, and shipping container forward strongback, carefully raise power turbine rotor until boltholes in shipping container forward strongback align with power turbine forward flange boltholes. NOTE

Install bolts equally spaced around power turbine forward flange. (7) c.

Using 54 bolts and nuts, attach shipping container forward strongback to power turbine forward flange. Tighten bolts to 160-210 lb in. (18.1-27.3 N⋅m) of torque.

Remove power turbine from maintenance dolly, 1C9372, as follows: NOTE

•

For use of lift fixture, 1C6955, refer to step (1). For use of aft lift and turn fixture, 1C8342, and shipping container forward strongback, refer to step (2).

•


•

Aft lift and turn fixture, 1C8342, cannot be used when installing power turbine into enclosure.

(1)

Install lift fixture, 1C6955 (figure 10), onto power turbine as follows: (a) Attach hoist to lift fixture, 1C6955, by engaging hoist hook in trolley clevis of lift fixture. (b) Position lift fixture, 1C6955, over power turbine assembly.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (c) Lower lift fixture, 1C6955, until lift pins in legs of forward yoke align with forward holes in ground handling mount fixtures, 1C8321, on power turbine. (d) Raise latch and slide lift pin into ground handling mount fixture, 1C8321, on both sides of power turbine. (e) Ensure spring stop returns latch to the down position to retain pins in the engaged position. (f) Using ball lock pins, attach aft brackets to ground handling mounts of TRF. (g) Remove two pins (12, figure 6) from ground handling mount fixtures, 1C8321. (h) Remove three pins (12, figure 7) from TRF ground handling mounts. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (i) Using hoist, lift power turbine from maintenance dolly, 1C9372. (j) (2)

Install power turbine into enclosure per WP 302 00.

Install aft lift and turn fixture, 1C8342 (figure 11), onto power turbine as follows: CAUTION

AFT LIFT AND TURN FIXTURE, 1C8342, CANNOT BE USED WITH POWER TURBINE FORWARD ADAPTER INSTALLED IN POWER TURBINE. (a) If installed, remove power turbine forward adapter per WP 220 00. (b) Using hoist, raise aft lift and turn fixture, 1C8342 (figure 11), and align behind TRF. (c) Using 32 capscrews, washers, and nuts, attach aft lift and turn fixture, 1C8342, to TRF aft flange. Tighten capscrews to 40-60 lb in. (4.6-6.7 N⋅m) of torque. (d) Install hoist and nylon sling onto shipping container forward strongback.




(e) Remove two pins (13, figure 6) from ground handling mount fixtures, 1C8321. (f) Remove three pins (12, figure 7) from TRF ground handling mounts. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (g) Using hoist(s), lift power turbine from maintenance dolly, 1C9372. (h) Install power turbine into shipping container per WP 503 00.




WORK PACKAGE

TECHNICAL PROCEDURES LUBE AND SCAVENGE PUMP SCREEN, ELECTRONIC CHIP DETECTOR, AND MAGNETIC DETECTOR PLUG INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 8 ................... 0


Page

Lube and Scavenge Pump Screen Inspection. ................................................................... Magnetic Detector Plug Inspection. ...................................................................................

3 3


GEK 105054 Volume II WP 400 00 1.


Introduction. This work package provides instructions for the inspection of the lube and scavenge pump, inlet and sump screens, electronic chip detectors, and the magnetic detector plug magnet located in the scavenge discharge tube. LM2500+ Model PK gas turbines use the six element lube and scavenge pump. LM2500+ Models GK and GV gas generators and LM2500+ Model PV gas turbines use the five element lube and scavenge pump.

2.

3.

4.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Troubleshooting Operation and Maintenance Manual, Volume II General Maintenance Practices Magnetic Detector Plug Replacement Illustrated Parts Breakdown

GEK 105054 Chapter 7 Chapter 9 GEK 105054 WP 002 00 WP 124 00 GEK 105055


Part No.

Multimeter

Local Purchase




Fed Spec TT-I-735 MIL-L-23699 or MIL-L-7808 736L680G01 R297P04 (Alt) Local Purchase

Safety Cable Safety Wire Soft Bristle Brush 5.


IPB Figure No./Item

Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing

59-58 59-60 59-62 59-64 59-87 59-88




7.

Magnetic Detector Plug Inspection. a.


b.

Remove magnetic detector plug per WP 124 00.

c.

Inspect magnetic detector plug magnet. If any foreign material is noted on magnet, inspect all lube and scavenge pump screens per paragraph 7.

d.

Reinstall magnetic detector plug per WP 124 00.

Lube and Scavenge Pump Screen Inspection. a.

Comply with all instructions contained with WP 002 00. NOTE Lube inlet screen does not have electronic chip detector installed in screen.

b.

Inspect lube and scavenge pump inlet screen (figure 1 or 2) as follows: WARNING

•


•


(1)

Place approved waste container under lube and scavenge pump to catch residual oil.

(2)

Tag screen with location. WARNING


Tag electronic chip detector electrical connector with location. Remove electrical connector per packager’s instructions.

(4)

Remove safety wire from screen and electronic chip detector.

(5)

Loosen and remove screen. Allow residual oil to flow into approved waste container. Remove and discard preformed packing.




Figure 1. Five Element Lube and Scavenge Pump Screens

Figure 2. Six Element Lube and Scavenge Pump Screens 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Remove electronic chip detector from screen. The electronic chip detectors thread into the screen assembly cap. Remove and discard preformed packing.

(7)

Inspect screen and electronic chip detector for foreign material as follows: NOTE

•

Bearing races, balls, and rollers are ferrous. The use of a magnet will help determine if these materials are present on screen.

•

Main engine bearing distress associated with increased lube scavenge temperatures and engine vibration. If foreign material is found, review engine log for significant changes in engine operating temperature or vibration readings. (a) If any material is found, note screen location to further isolate probable source of material. NOTE

Electronic chip detectors are located in all sump scavenge screens. (b) Remove electronic chip detector from screen. Visually inspect electronic chip detector tip (figure 3) for foreign material. (c) If material found is identified as pieces of preformed packing, gasket, safety wire, coke, machining chip, and/or rub strip material, place engine on watch as follows:

(8)

1

Inspect and clean lube and scavenge pump screens and monitor lube system parameters daily until source of contamination is located.

2

Engine can be removed from watch status and returned to normal inspection schedule if screens are free of debris for 2 consecutive days.

If materials are found, refer to table 1 for disposition.




Figure 3. Electronic Chip Detector Tip Buildup Table 1. Possible Causes of Foreign Material Screen

Possible Cause

Reference

Accessory Gearbox (AGB)

a.

AGB failure

GEK 105054, Chapter 9

b.

Starter failure


Lube Inlet

Packager oil supply system

Packager’s manual

A-sump

No. 3R bearing failure, Inlet Gearbox (IGB), Transfer Gearbox (TGB)


B-sump

No. 4R and/or No. 4B bearing failure


a.

No. 5R bearing failure


b.

No. 6R bearing failure


No. 7R and/or No. 7B bearing failure


C-sump D-sump




Clean screen and electronic chip detector as follows: WARNING

ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. (a) Using isopropyl alcohol and soft bristle brush, gently clean screen and electronic chip detector tip. WARNING WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG. WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS. (b) Using shop air, dry screen and electronic chip detector. (c) Replace any screen that is damaged. (10) If electronic chip detector is suspected of malfunctioning, check as follows: (a) Using multimeter, check for continuity between electrical connector pins and electronic chip detector housing. There shall be no continuity between pins and housing. (b) Using multimeter, check for continuity between electrical connector pins. Resistance shall not be less than 10 kiloohms when clean. (c) If electronic chip detector does not meet parameters of substep (a) or (b), replace electronic chip detector. WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (11) Coat new preformed packings for screen and electronic chip detector with lubricating oil. (12) Install preformed packing onto screen. (13) Reinstall screen into lube and scavenge pump. Tighten screen to 55-70 lb in. (6.3-7.9 N⋅m) of torque and safety-wire. Remove location tag.




(14) Install preformed packing onto electronic chip detector. (15) Reinstall electronic chip detector into screen. The electronic chip detectors thread into the screen assembly cap. Tighten to 480-570 lb in. (54.2-64.4 N⋅m) of torque and safety wire. WARNING ELECTRICAL POWER SHALL BE OFF BEFORE CONNECTING OR DISCONNECTING ELECTRICAL CONNECTORS. ELECTRICITY CAUSES SHOCK, BURNS, AND DEATH. (16) Reinstall electronic chip detector electrical connector per packager’s manual. Remove tag. c.

Inspect both lube and scavenge pump accessory gearbox (AGB) screens and electronic chip detector per steps b.(1) through (16).

d.

Inspect lube and scavenge pump A-sump screen and electronic chip detector per steps b.(1) through (16).

e.

Inspect lube and scavenge pump B-sump screen and electronic chip detector per steps b.(1) through (16).

f.

Inspect lube and scavenge pump C-sump screen and electronic chip detector per steps b.(1) through (16). NOTE D-sump screen is located on six element lube and scavenge pumps only.

g.

Inspect lube and scavenge pump D-sump screen and electronic chip detector per steps b.(1) through (16).

h.

Turn on lubricating oil supply flow to lube and scavenge pump per packager’s manual.

i.

Motor engine for 2 minutes per GEK 105054, Chapter 7, to purge lube system of air and check for leaks.




WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR INLET INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Centerbody Inspection. ....................................................................................................... Gas Generator Inlet Duct Inspection. ................................................................................ Paint Application.................................................................................................................

4 3 6


GEK 105054 Volume II WP 401 00 1.


Introduction. This work package provides instructions for the inspection of the gas generator inlet area and parts repair and replacement criteria.

2.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Gas Generator Inlet Duct Replacement Centerbody Replacement

GEK 105054 WP 002 00 WP 204 00 WP 205 00

3.


4.



Chromate Free Primer Paint Epoxy Polymide Topcoat Paint Safety Cable Safety Wire Silicone Rubber Adhesive

MIL-P-2444/1 MIL-C-22750 736L680G01 R297P04 (Alt) GE Spec A15F6A3 (RTV 103) Black Local Purchase

Shop Rags 5.





Gas Generator Inlet Duct Inspection. a.

Comply with all instructions contained with WP 002 00.

b.

If installed, inspect inlet screen per packager’s manual.

c.

If installed, remove inlet screen per packager’s manual.

d.

Inspect gas generator inlet duct per table 1.

e.

If required, install inlet screen per packager’s manual. Table 1. Inlet Duct Inspection

Inspect

On-Site Maximum Serviceable Limits

On-Site Maximum Repairable Limits

On-Site Corrective Action

INLET DUCT (figure 1) 1. Assembly (unless otherwise specified) for: a.

Cracks

Not serviceable

Not repairable

Replace inlet duct per WP 204 00*

b.

Nicks and scores (except on water inlet fitting)

Any number, any length, 0.031 in. (0.78 mm) deep, after removal of high metal

Not repairable

Blend to remove high metal

c.

Dents

Any number, smooth dents, 0.25 in. (6.3 mm) deep, except on mating surfaces

Not repairable

Replace inlet duct per WP 204 00*

d.

Missing paint

Any amount, if no parent metal is exposed

Any amount

Touch up paint per paragraph 8

e.

Plugged wash discharge holes

Not serviceable

Any amount

Using small wire or No. 57 (0.043 in. [1 mm]) drill bit, remove contamination

f.

Dirty airflow path surface

Serviceable

g.

Loose installation fasteners

Not serviceable

Wipe clean, if inlet screen has been removed for other maintenance action Any amount

Retorque fastener



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Inlet Duct Inspection - Cont.

Inspect




1. Assembly (unless otherwise specified) for: - (cont.) h.

Leakage at water wash inlet connection

Not serviceable

Any amount

Retorque connection per packager’s manual

* May be repairable. Consult GE for disposition of replaced parts. 7.

Centerbody Inspection. a.


b.

Remove inlet duct and screen per WP 204 00.

c.

Inspect centerbody per table 1.

d.

Reinstall inlet duct and screen per WP 204 00. Table 2. Centerbody Inspection

Inspect




CENTERBODY (figure 1) 1. Assembly for: a.

Cracks

Not serviceable

b.

Dirty airflow path surface

Serviceable

Not repairable

Replace centerbody per WP 205 00* Wipe clean, if inlet screen has been removed for other maintenance action

WARNING VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELL-VENTILATED AREA. c.

Loose bolts

Not serviceable

Any amount

Retighten and safety-wire. Apply adhesive, RTV-103

* May be repairable. Consult GE for disposition of replaced parts. 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Inlet Duct and Centerbody 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 401 00 8.


Paint Application. WARNING PAINTS, PRIMERS, AND THINNERS ARE FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. USE IN A WELL-VENTILATED AREA. FOR SPRAY APPLICATIONS, RESPIRATORY PROTECTION IS ALSO REQUIRED. a.

Paint area as follows: (1)

Apply one coat of chromate free primer.

(2)

Apply one coat of topcoat paint to match surrounding color.




WORK PACKAGE

TECHNICAL PROCEDURES EXTERNAL ENGINE CLEANING (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject External Engine Cleaning. .................................................................................................

3


GEK 105054 Volume II WP 402 00 1.


Introduction. This work package contains instructions for cleaning the external surfaces of LM2500+ Models GK and GV gas generators and Model PK gas turbine. For PV gas turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown, for further instructions.

2.


Title

For LM2500+ Models GK and GV gas generators, and Model PK gas turbine: Operation and Maintenance Manual, Volume I GEK 105054 Installation/Initial Startup and Engine Operation Chapter 7 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 For PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


4.


5.

Nomenclature


Isopropyl Alcohol

Fed Spec TT-I-735





External Engine Cleaning. a.


b.

Clean engine as follows: (1)

If portable steam cleaning equipment is available: (a) Prepare steam cleaning equipment per manufacturer’s instructions. WARNING

STEAM CLEANING CAN CAUSE SERIOUS BURNS. WEAR PROTECTIVE GLOVES, APRON, AND FACE SHIELD DURING STEAM CLEANING PROCESS. (b) Using portable steam cleaning equipment, clean all external surfaces of engine. (2)

If portable steam cleaning equipment is not available, clean engine as follows: WARNING

SERIOUS INJURY CAN OCCUR WHEN APPLYING HYDRAULIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS. (a) Using flexible hose with adjustable spray nozzle and 50-60 gallons (189-227 liters) of clean water, wash engine exterior and its components. Maintain water pressure of 40-45 psi (276-310 kPa). WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. (b) If water will not remove contamination, apply isopropyl alcohol to affected area. (c) Allow isopropyl alcohol to soak for 2 hours, minimum. (d) Flush contaminated area with clean water. (3)

If contamination is not removed, repeat step (1) or (2), as required, until contamination is removed from external engine surfaces.




c.

Dispose of waste water in accordance with local regulations

d.

Start engine and idle for 5 minutes per GEK 105054, Chapter 7.




WORK PACKAGE

TECHNICAL PROCEDURES EXTERNAL ENGINE INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 23 ................. 0 24 Blank............ 0 Alphabetical Index Page

Subject Gas Generator External Inspection. .................................................................................. Power Turbine External Inspection. ..................................................................................

3 3


GEK 105054 Volume II WP 403 00 1.


Introduction. This work package contains instructions for visually inspecting external engine surfaces and components of LM2500+ Models GK and GV gas generators and Model PK gas turbine. For instructions on external inspection of the PV gas turbine, refer to GEK 105052, Operation and Maintenance Manual and GEK 105053, Illustrated Parts Breakdown.

2.


Title

For LM2500+ Models GK and GV gas generators, Model PK gas turbine, and GE supplied six stage power turbine: Operation and Maintenance Manual, Volume I GEK 105054 General Maintenance Practices Chapter 10 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Gas Generator Outside Piping and Wiring Removal and Installation WP 113 00 Gas Turbine Outside Piping and Wiring Removal and Installation SWP 113 01 Turbine Mid Frame Replacement WP 200 00 Accessory Gearbox Replacement WP 206 00 Compressor Front Frame Replacement WP 210 00 Compressor Stator Casings Replacement WP 211 00 Six Stage Power Turbine Casings Removal and Installation WP 218 00 Gas Generator Assembly Replacement WP 301 00 Power Turbine Assembly Replacement WP 302 00 Gas Generator Inlet Inspection WP 401 00 Variable Stator Vane System Inspection WP 418 00 For PV gas turbines: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


4.


5.




7.


Gas Generator External Inspection. a.


b.

Inspect hoses, tubes, and fittings per table 1.

c.

Inspect electrical cables and connectors per table 2.

d.

Inspect inlet duct and centerbody per WP 401 00.

e.

Inspect compressor front frame (CFF) per table 3.

f.

Inspect accessory gearbox (AGB) and air/oil separator per table 4.

g.

Inspect high pressure compressor (HPC) stator casings per table 5.

h.

Inspect variable stator vane (VSV) components per WP 418 00.

i.

Inspect compressor rear frame (CRF) per table 6.

j.

Inspect turbine mid frame (TMF) per table 7.

Power Turbine External Inspection. a.

Inspect hoses, tubes, and fittings per table 1.

b.

Inspect electrical cables and connectors per table 2.

c.

Inspect power turbine stator assembly per table 8.

d.

Inspect turbine rear frame (TRF) per table 9.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Tubes, Hoses, and Fittings

Inspect




1. Tubing for: a.

Cracks and splits

Not serviceable

Not repairable

Replace assembly

b.

Wrinkles and kinks in bend ID

Two percent depth of wrinkle or kink of tube OD

Not repairable

Replace assembly

c.

Dents and flat areas

Any amount of deviation from contour, within 20 percent of original tube OD

Not repairable

Replace assembly

d.

Nicks and scores

Any amount, 0.005 in. (0.127 mm) deep


Blend to remove damage per WP 002 00, but not beyond depth of damage. Contour shall be smooth and polished

e.

Wear at clamping locations (not including wear sleeves)



Blend to remove damage per WP 002 00, but not beyond depth of damage. Contour shall be smooth and polished

2. Tube Fittings and Connectors for: a.

Leakage

Not serviceable

Light polishing of entire sealing (mating) surfaces to remove scratches is allowed

Polish sealing surface and retorque or replace tube assembly per WP 113 00 or SWP 113 01

b.

Looseness

Not serviceable

Any amount

Retorque. Refer to WP 113 00 or SWP 113 01



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Tubes, Hoses, and Fittings - (Cont.)

Inspect




3. Hoses for: a.

Broken braid wires

Three wires per plait (a band of interwoven wires) and no more than six broken wires per assembly

Not repairable

Replace hose assembly per WP 113 00 or SWP 113 01

b.

Crimps

Not serviceable

Not repairable

Replace hose assembly per WP 113 00 or SWP 113 01

4. Hose Fittings and Connectors for: a.

Leakage

Not serviceable


Polish sealing surface and retorque or replace tube assembly per WP 113 00 or SWP 113 01

b.

Looseness

Not serviceable

Any amount

Retorque per WP 113 00 or SWP 113 01



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Electrical Cables and Connectors

Inspect




1. Electrical Cables for: a.

Broken braid

50 percent of exterior braid wires may be broken, if circuit continuity is maintained

Not repairable

Replace assembly per WP 113 00 or SWP 113 01

b.

Kinks or crimps

Any amount, if circuit continuity is maintained. Insulation resistance pin-topin and pin-to-shell shall be 1 megohm minimum

Not repairable


c.

Security of installation

Supported at max of 12 in. (305 mm) intervals. No relative motion between cable and contacted hardware

Any amount

Reclamp cable per WP 113 00 or SWP 113 01

2. Connectors for: a.

Back shell potting separation, tears, and cracks

Not serviceable

Not repairable


b.

Loose nut

Not serviceable

Any amount

Tighten hand-tight

c.

Seal

Each connector joint shall have seal installed

Any amount

Replace seal if damaged or missing

d.

Braid/ connector separation

50 percent of wires shall be secure and circuit continuity maintained

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Electrical Cables and Connectors - (Cont.)

Inspect




3. Electrical Connector Pins For: a.

Distortion

Shall assemble to mating connector

Any amount correctable by straightening pins

Straighten pins or replace assembly per WP 113 00 or SWP 113 01

b.

Fracture

Not serviceable

Not repairable


c.

Corrosion/ Contamination

No visible corrosion permitted

-

Clean surface corrosion

Any amount, if continuity is maintained. Insulation resistance pin-topin and pin-toshell shall be 1 megohm minimum

Not repairable


4. Insert for: a.

Cracks

5. Shell for: a.

Distortion

Shall assemble to mating connector and seal

Not repairable


b.

Cracks

Not serviceable

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Compressor Front Frame

Inspect




1. All Surfaces (Except Forward Mounts) for: a.

Dents

Any number smooth contour dents 0.125 in. (3.17 mm) deep, with minimum separation of 2.00 in. (50.8 mm)

_

Replace CFF per WP 210 00

b.

Nicks, scratches, and gouges

Any number 0.031 in. (0.78 mm) deep, with minimum separation of 1.00 in. (25.4 mm), after removal of high metal

_

Remove high metal

One complete thread may be removed or any amount of damage

Chase threads

_

Replace CFF per WP 210 00

2. Threaded Pads, Ports, and Bosses for: a.

Damaged threads

Not serviceable

Install helical coil wire insert or threaded insert

3. Forward Mounts for: a.

Cracks

Not serviceable



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Accessory Gearbox and Air/Oil Separator

Inspect




1. Accessory Gearbox and Air/Oil Separator for: a.

Cracks

Not serviceable

Not repairable

Replace AGB per WP 206 00 or replace Air/Oil Separator per WP 116 00

b.

Nicks, scores, and scratches on nonmachine surfaces

Any number, any length 0.031 in. (0.78 mm) deep

Not repairable

Replace AGB per WP 206 00 or replace Air/Oil Separator per WP 116 00

NOTE Excessive oil leakage from accessory gearbox may be due to omission of accessory drive gear plug. c.

Leaking plugs or fittings

Not serviceable

Any amount

Retighten loose fittings or replace damaged preformed packing

d.

Missing or broken safety wire

Not serviceable

Any amount

Replace safety wire

2. Studs for: a.

Thread damage

Not serviceable

Total of 75 percent of one full thread may be removed

Blend per GEK 105054, Chapter 10

b.

Looseness

Not serviceable

See corrective limits column

Tighten stud one turn. If still not tight, replace AGB per WP 206 00



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. High Pressure Compressor Stator Casings

Inspect




NOTE Hot spots and bulges indicate internal damage in that area. Assess condition by borescope inspection. 1. HPC Forward Stator Casings for: a.

Cracks

Not serviceable

Not repairable

Replace HPC forward stator casings per WP 211 00

b.

Grooves worn by actuation ring spacers

Any number, 0.015 in. (0.38 mm) deep, after removal of high metal

Not repairable


c.

Hot spots (discoloration)

Serviceable if metal is not granular and cracks are not present

Not repairable


d.

Bulges

Not serviceable when associated with heat discoloration

Not repairable


e.

Nicks, gouges, and scratches in: One per each 4 in. (26 cm) area, 0.015 in. (0.38 mm) deep, 1.00 in. (25.4 mm) long, after removal of high metal, if no sharp areas appear

Not repairable


(1)

Casing skin and manifolds



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. High Pressure Compressor Stator Casings - (Cont.)

Inspect




1. HPC Forward Stator Casings for: - (cont.) (2)

Flanges and ribs

Any number, 0.063 in. (1.60 mm) deep, 0.50 in. (12.7 mm) long, with minimum separation of 2.00 in. (50.8 mm), after removal of high metal

Not repairable


2. HPC Rear Stator Casings for: a.

b.

Cracks in: (1)

Casing skin and manifolds, cracks emanating from horizontal and vertical boltholes

Not serviceable

Not repairable

Replace HPC rear stator casings per WP 211 00

(2)

Casing ribs

One crack, 0.25 in. (6.3 mm) long, and two weld cracks, 0.065 in. (1.60 mm) long per rib in weld or heat affected zone that shall not allow air leakage and does not extend into casing skin

Not repairable


Serviceable, if metal is not granular and cracks are not present

Not repairable





LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. High Pressure Compressor Stator Casings - (Cont.)

Inspect




2. HPC Rear Stator Casings for: - (cont.) c.

Bulges

Not serviceable when associated with heat discoloration

Not repairable


d.

Nicks, dents, scratches, and gouges in casing skin

Any number, 0.015 in. (0.40 mm) deep, 0.50 in. (12.7 mm) long, after removal of high metal

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Compressor Rear Frame

Inspect




1. Flanges for: a.

Cracks in boltholes

One per flange radially outward

Not repairable

Replace gas generator per WP 301 00

2. All Pads for: a.

Cracks

Two per weld, 0.13 in. (3.3 mm) long with minimum separation of 2.00 in. (50.8 mm), if none extend into parent metal. None allowed in fuel nozzle pads

Not repairable


b.

Nicks, scores, and scratches

Any number on sealing surface, 0.031 in. (0.78 mm) deep, not extending across more than 50 percent of sealing surface, after removal of high metal

Not repairable


c.

Thread damage (except nozzle pad)

Not serviceable


Chase threads

Thread damage on fuel nozzle pad

Not serviceable


Chase threads

d.

Install helical coil wire insert

Install helical coil wire insert or threaded insert



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Compressor Rear Frame - (Cont.)

Inspect 3. Tubes for: a. Cracks

b.

Nicks and scratches

c.

Dents

4. Strut Pads for: a. Cracks

b.

Nicks and scratches

c.

Dents


Dents


Not serviceable

Not repairable

Any number, 0.010 in. (0.25 mm) deep, after removal of high metal Any number smooth contour dents, 0.063 in. (1.60 mm) deep

Not repairable

Not repairable


Boltholes may be cracked through radially outward, one hole per pad Any number, any length 0.063 in. (1.60 mm) deep, after removal of high metal, if metal is not reduced to less than 75 percent original thickness Any number smooth contour dents, 0.25 in. (6.3 mm) deep, except on mating surfaces

Not repairable


Not repairable


Not repairable


Not repairable

Replace gas generator per WP 301 00 Replace gas generator per WP 301 00

5. Outer Case Skin for: a. Cracks Not serviceable

b.


Any number smooth contour dents, 0.25 in. (6.3 mm) deep

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Compressor Rear Frame - (Cont.)

Inspect




5. Outer Case Skin for: - (Cont.) c.


Axial direction: any number, 0.063 in. (1.60 mm) deep, 1.00 in. (25.4 mm) long. Circumferential direction: 0.031 in. (0.79 mm) deep, 1.00 in. (25.4 mm) long with minimum separation of 1 in. (25.4 mm), after removal of high metal

Not repairable


d.

Inspection bosses for thread damage

Not serviceable


Chase threads.

e.


Any number, if metal is not crazed. No cracks allowed. Perform borescope inspection of combustion liner, if hot spots are noted

Not repairable


f.

Bulges

Not serviceable when associated with heat discoloration. Perform borescope inspection of combustion liner if bulges are noted

Not repairable


Install helical coil wire insert



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. Turbine Mid Frame

Inspect




1. Casing for: a.

Cracks

Any number, 0.125 in. (3.18 mm) long, that shall not permit air or fluid leakage. 1.00 in. (25.4 mm) minimum separation between cracks

Not repairable

Replace TMF per WP 200 00

b.

Nicks, dents, gouges, etc.

Any number, 0.063 in. (1.60 mm) deep, 1.00 in. (25.4 mm) long, if metal is not thinned to less than 75 percent of original thickness

Not repairable


c.

Distortion

Acceptable, if proper assembly can be made

Not repairable


d.


Serviceable, if metal is not crazed and cracks are not present. Perform borescope inspection of combustion area if bulges are noted

Not repairable


e.

Bulges

Not serviceable when associated with heat discoloration. Perform borescope inspection of combustion area if bulges are noted

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. Turbine Mid Frame - (Cont.)

Inspect




2. Service Tube Pads and Instrumentation Bosses for: a.

Nicks, gouges, etc., on flange mating surface

0.031 in. (0.79 mm) deep, extending across not more than 50 percent of sealing surface, after removal of high metal

Not repairable


Not serviceable

One complete thread may be removed

Chase threads

3. All Threaded Ports and Bosses for: a.

Damaged threads

4. Tubes for: a.

Cracks

Not serviceable

Not repairable


b.


0.010 in. (0.25 mm) deep, after removal of high metal

Not repairable


c.

Dents


Not repairable


5. Liner for: a.

Cracks in skin (no separation through aft ring)

Any number, not exceeding 2.00 in. (50.8 mm) length, and not joining with adjacent cracks. Monitor for crack propagation by borescope inspection at each opportunity, but not later than 500 hours of operation

Not repairable


b.

Missing material

Not serviceable

Not repairable





Inspect




5. Liner for: - (cont.) c.

Buckling or distortion

Any amount, 0.25 in. (6.3 mm) from original contour

Not repairable


6. Front Flange for: a.

Cracks extending from boltholes in any direction

Not serviceable

_


b.

Cracks not extending from boltholes

Any number, 0.016 in. (0.41 mm) long, with 2.00 in. (50.8 mm) min spacing between cracks

_


c.


Any number, any length, 0.031 in. (0.78 mm) deep not extending across more than 75 percent of flange face after removal of high metal

_

Blend

7. Rear Flange for: a.

Cracks extending between boltholes

Not serviceable

_


b.

Cracks extending from boltholes to outer edge of flange

Two cracks per flange provided adjacent holes not cracked

_





Inspect




7. Rear Flange for: - (cont.) c.


Any number, any length, 0.031 in. (0.78 mm) deep, not extending across more than 75 percent of flange face after removal of high metal

_

Blend



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 8. Power Turbine Stator Assembly

Inspect




1. Front Flange for: a.


Not serviceable

Not repairable

Replace power turbine stator casings per WP 218 00

b.

Cracks not extending from boltholes

Any number, 0.016 in. (0.40 mm) long, with 2.00 in. (50.8 mm) minimum spacing between cracks

Not repairable


c.


Any number, any length, 0.031 in. (0.78 mm) deep, not extending across more than 75 percent of flange face, after removal of high metal

_




Not serviceable

Not repairable


b.


Two cracks per flange, if adjacent holes not cracked

Not repairable


c.



_




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 8. Power Turbine Stator Assembly - (Cont.)

Inspect




3. Horizontal Flanges for: a.


Two cracks per flange, if mating flange on outer half of casing does not have cracks at same holes

Not repairable


b.



_

Blend per GEK 105054, chapter 10

4. Casing Body for: a.

Cracks

Any number, 0.063 in. (1.60 mm) long with 2.0 in. (50.8 mm) minimum spacing

Not repairable


b.

Nicks


Not repairable


c.

Scratches

Any number, 0.010 in. (0.25 mm) deep, any length

Not repairable


d.

Dents

Any number, 0.125 in. (3.18 mm) deep, if assembly can be accomplished

Not repairable


e.

Distortion

Free-state distortion acceptable, if assembly can be accomplished

Not repairable

Replace power turbine stator casings per WP 218 00 21



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 9. Turbine Rear Frame

Inspect




1. All Surfaces for: a.



Not repairable

Replace power turbine per WP 302 00

b.

Dents


Not repairable


2. All Casings Surfaces (Unless Otherwise Specified) for: a.

Cracks (all surfaces except hat-section stiffeners)

Not serviceable

Not repairable


b.


Any number, any length, 0.031 in. (0.79 mm) deep, after removal of high metal on all surfaces

Not repairable


c.

Dents


Not repairable


Not repairable


3. All Mount Surfaces for: a.

Cracks

Not serviceable



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 9. Turbine Rear Frame - (Cont.)

Inspect




4. Strut Fairing for: a.

Loose or missing rivets 1.

Forwardaft end rivets (fairing-tocasings),

Any number

Not repairable


2.

Side rivets (fairing to casings)

One per strut side, if end rivets are in place

Not repairable


3.

Trailing edge (fairing)

One per strut

Not repairable





WORK PACKAGE

TECHNICAL PROCEDURES GAS TURBINE EXHAUST SYSTEM INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS PK AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Gas Turbine Exhaust System Inspection...........................................................................

3


GEK 105054 Volume II WP 404 00 1.


Introduction. This work package provides instructions for inspecting LM2500+ Model PK gas turbine exhaust system. For LM2500+ Model PV gas turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown, for further inspection instructions.

2.


Title For LM2500+ Model PK gas turbine: Operation and Maintenance Manual, Volume II General Maintenance Practices For LM2500+ Model PV gas turbine: Operation and Maintenance Manual Illustrated Parts Breakdown 3.


4.


5.


GEK 105054 WP 002 00 GEK 105052 GEK 105053




Gas Turbine Exhaust System Inspection. a.


b.

For enclosures with two stage high speed power turbine installed, refer to GEK 105052 for applicable instructions.

c.

For enclosures with six stage power turbine, refer to packager’s manual.

d.

For enclosures with gas generator only, or with OEM power turbine installed onto gas generator, refer to packager’s manual.




WORK PACKAGE

TECHNICAL PROCEDURES WATER-WASH (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 8.................... 0


Page

Crank/Soak Cleaning. ......................................................................................................... On-Line High Pressure Compressor Cleaning. ................................................................. Water and Detergent Requirements. ................................................................................. Water-Wash Description.....................................................................................................

4 7 3 3


GEK 105054 Volume II WP 405 00 1.


Introduction. This work package contains instructions for performing water-wash procedures on LM2500+ Models GK and GV gas generators and Model PK gas turbines. For LM2500+ Model PV gas turbine, refer to Operations and Maintenance Manual, GEK 105052 and Illustrated Parts Breakdown, GEK 105053, for further instructions.

2.


Title

For LM2500+ Models GK and GV gas generators and Model PK gas turbine: Operation and Maintenance Manual, Volume I GEK 105054 Installation/Initial Startup and Engine Operation Chapter 7 Water Requirements Appendix A Liquid Detergent Requirements Appendix A Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Requirements WP 002 00 For LM2500+ Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


4.

Consumable Material. Nomenclature Antifreeze: Isopropyl Alcohol Monopropylene Glycol (PG) Detergent: Airworthy ZOK.mx (water base) Airworthy ZOK27 & ZOK 27LA (water base) Ardrox 6322 (solvent base) B&B 3100 (solvent base) B&B TC-100 (water base) Castrol Techniclean GT (water base) Conntect 5000 and 6000 (water base) JAD MA-109C and MA-112 (water base) Minco Turboklenz/Protoklenz (solvent base) Protoklenz (water base) R-MC compressor wash (water base) Rochem Fyrewash (solvent base) Turbo K (water base) Turbotect 950 (water base) Turco T-6783

5.

Part No./Specification Fed Spec TT-I-735 Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase





Water-Wash Description. a.

7.

Perform basic water-wash procedures using the following methods: (1)

Crank/Soak Cleaning: Applied while motoring high pressure compressor (HPC) rotor. Used to perform thorough cleaning of engine.

(2)

On-line Cleaning: Applied while engine is running. Used for extending interval between crank/soak water washes.

Water and Detergent Requirements. a.

Water quality and liquid detergent for crank/soak compressor cleaning shall meet requirements specified in GEK 105054, Appendix A.

b.

Liquid detergents conforming to step a. and including those listed below may be used for performing water-wash procedures. Follow liquid detergent manufacturer’s instructions for recommended detergent/water dilution ratios. Ensure that detergents used, including those listed, meet packager requirements.

•

B&B 3100, B&B TC-100

•

Ardrox 6322

•

R-MC compressor wash

•

Airworthy ZOK27, ZOK 27LA, and ZOK.mx

•

Turbo K

•

Turbotect 950 and Turbotect ARF

•

Minco Turboklenz/Protoklenz

•

Castrol Techniclean GT

•

JAD MA-109C and MA-112

•

Conntect 5000 and 6000

•

Turco T-6783

•

Other detergents that meet requirements of GEK 105054, Appendix A WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA

c.

If outside air temperature is at or below 50°F (10°C), mix isopropyl alcohol or monopropylene glycol (PG) with cleaning solution. Refer to packager’s manual or detergent manufacturer’s literature for recommended solution mixtures and additional information. 3 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 405 00 8.


Crank/Soak Cleaning. a.


b.

Before initiating crank/soak cleaning sequence, comply with following requirements:

c.

(1)

If crank/soak cleaning is not preceded by an extended shutdown period, perform normal shutdown per GEK 105054, Chapter 7.

(2)

Allow engine to cool so outside surfaces are less than 200°F (93.3°C).

(3)

To expedite cooling, motoring engine using starter is permissible. Motoring procedures are contained in GEK 105054, Chapter 7.

Prepare water-wash solution as follows: WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. CAUTION

•

ENSURE CHECKLISTS HAVE BEEN ESTABLISHED FOR PACKAGER-FURNISHED EQUIPMENT. CONSULT PACKAGER’S MANUAL FOR MANDATORY PRESTART PROCEDURES. ENSURE PACKAGER FURNISHED LUBE OIL SUPPLY SYSTEM IS ACTIVATED AND OPERATIONAL PRIOR TO ANY MOTORING SEQUENCE. OTHERWISE, DAMAGE MAY RESULT.

•

USE OF NON-ISOPROPYL ALCOHOL, ETHYLENE GLYCOL, OR ADDITIVES CONTAINING CHLORINE, SODIUM, OR POTASSIUM ARE NOT PERMITTED. OTHERWISE, DAMAGE MAY RESULT.

(1)

Chemical properties of the wash water, rinse water, and detergent shall conform to parameters established in paragraph 7.

(2)

If outside air temperature is at, or below, 50°F (10.0°C), proceed as follows: (a) Add isopropyl alcohol or monopropylene glycol (PG) to wash. Refer to GEK 105054, Appendix A.




(b) Off-line wash shall not be accomplished with outside air temperature below 30°F (-34.4°C). (3)

Prepare 20 gallons (76 liters) of water-wash solution as follows: NOTE

The suggested dilution requirement is based on experience with several detergents. Refer to specific detergent manufacturer instructions for proper dilution requirements. (a) Mix 19 gallons (72 liters) of water/antifreeze solution to 1 gallon (3.8 liters) of detergent in packager supplied water-wash tank. (b) Wash solution temperature shall be 100 to 150°F (37.8 to 66°C). WARNING SERIOUS INJURY CAN OCCUR WHEN APPLYING PNEUMATIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS. (c) Apply 45-55 psig (310-379 kPa) air pressure to packager supplied water-wash tank per packager’s manual. d.

Apply water-wash cleaning solution as follows: WARNING CLEANING SHALL BE PERFORMED IN A CLEAN, WELL-VENTILATED AREA. PROTECTIVE CLOTHING AND GLOVES SHALL BE WORN. EXTINGUISHERS AND VAT OR TANK COVERS SHALL BE AVAILABLE IN CASE OF FIRE. CAUTION ENSURE ENCLOSURE AREA SHALL BE VENTILATED. THE ENGINE SHALL BE SHUT DOWN AND COOLED PRIOR TO CRANK/SOAK CLEANING. ALL DRAINS SHALL BE OPEN. (1)

Motor gas generator per GEK 105054, Chapter 7.

(2)

When HPC rotor begins to rotate, apply water-wash solution per packager’s manual.

(3)

As HPC rotor speed reaches 1,200 rpm, de-energize starter and cease applying waterwash solution per packager’s manual.

(4)

Allow HPC rotor speed to decrease.




(5)

As HPC rotor speed reaches 0-100 rpm, re-energize starter and repeat steps (1) through (4) until all water-wash solution is used.

(6)

Allow engine to coast to stop. NOTE

•

During the wash and rinse cycle, some of the solution may leak through the engine casings and openings to the exterior of the engine.

•

Required soak time will depend on nature and degree of contamination.

e.

Allow water-wash solution to soak on engine components for a minimum of 10 minutes.

f.

Prepare rinse solution as follows: WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. (1) If outside air temperature is at, or below 50°F (10.0°C), add isopropyl alcohol or monopropylene glycol (PG) to prevent rinse solution from freezing. Refer to GEK 105054 , Appendix A. (2) Fill water-wash tank with 40 gallons (151.4 liters) of water or water/antifreeze solution. (3) Rinse solution temperature shall be 100 to 150°F (37.8 to 66.0°C). WARNING SERIOUS INJURY CAN OCCUR WHEN APPLYING PNEUMATIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS. (4) Apply 45-55 psig (310.3-379.2 kPa) air pressure to packager supplied water-wash tank per packager’s manual. CAUTION RESIDUAL WASTE FOLLOWING WATER-WASH SHALL BE DISPOSED OF IN ACCORDANCE WITH LOCAL ENVIRONMENTAL REGULATIONS FOR SPECIFIC LOCATIONS. USERS SHALL CONTACT THE SPECIFIC MANUFACTURER FOR DETAILS RELATIVE TO SAFE DISPOSAL OF THE PRODUCT. OTHERWISE, ENVIRONMENTAL CONTAMINATION MAY RESULT.




9.

g.

Rinse per steps d.(1) through d.(6) until all rinse solution is used.

h.

Inspect engine inlet. If not sufficiently clean, repeat cleaning cycle. If all cleaning solution is not removed from engine, repeat rinse cycle.

i.

Within 30 minutes of off-line wash/rinse cycle completion, perform following steps: (1)

Start and operate engine at idle for a period of 5 minutes per GEK 105054, Chapter 7.

(2)

Initiate normal operation. If engine operation is prohibited during this period, motor engine per GEK 105054, Chapter 7, for 5 minutes, minimum.

On-Line High Pressure Compressor Cleaning. a.

Comply with all instructions contained with WP 002 00. NOTE

b.

•

On-line compressor cleaning may be beneficial to those users who are particularly sensitive to decreased performance and down-time required for off-line (crank/soak) compressor cleaning. On-line compressor cleaning is intended to supplement the off-line cleaning procedure and is not intended as a replacement.

•

Experience has shown that the use of water alone, without the addition of detergents, may be effective at on-line compressor cleaning. The addition of a cleaning solution may be required dependent upon the type and amount of deposits on the compressor gas path surfaces.

Chemical properties of the wash water, rinse water, and detergent shall conform to parameters established in paragraph 7. WARNING ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELLVENTILATED AREA. CAUTION THE USE OF NON-ISOPROPYL ALCOHOL, ETHYLENE GLYCOL, OR ADDITIVES CONTAINING CHLORINE, SODIUM, OR POTASSIUM ARE NOT PERMITTED.

c.

If outside air temperature is at, or below 50°F (10°C), proceed as follows: (1)

Add isopropyl alcohol or monopropylene glycol (PG) to prevent wash solution from freezing. Refer to GEK 105054, Appendix A. 7


GEK 105054 Volume II WP 405 00 (2)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines On-line wash shall not be accomplished with outside air temperature below 20°F (-7°C). CAUTION

RESIDUAL WASTE FOLLOWING WATER-WASH SHALL BE DISPOSED OF IN ACCORDANCE WITH LOCAL ENVIRONMENTAL REGULATIONS FOR SPECIFIC LOCATIONS. USERS SHALL CONTACT THE SPECIFIC MANUFACTURER FOR DETAILS RELATIVE TO SAFE DISPOSAL OF THE PRODUCT. d.

Prepare on-line wash solution with water and detergent per packager’s manual. NOTE Recommended flow rate of wash solution is 5+/−1 gpm.

e.

Limit total amount of on-line wash solution/water to 100 gal/day (378.54 liters/day) maximum and 4-6 gpm (15.14-22.71 liters/minute).

f.

Refer to packager’s manual for specific amount of wash solution and frequency of on-line wash.

g.

It is recommended that the gas turbine be taken off temperature control during on-line wash procedure




WORK PACKAGE

TECHNICAL PROCEDURES BORESCOPE INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 59.................. 1 60 Blank ........... 1


Page

Borescope Inspection........................................................................................................... 11 Definitions. .......................................................................................................................... 8 Engine Preparation for Borescope Inspection. .................................................................. 4 Engine Preparation for Operation...................................................................................... 58


1

GEK 105054 Volume II WP 406 00 1.


Introduction. This work package contains instructions for borescope inspection of LM2500+ Models GK and GV gas generators, Models PK and PV gas turbines, and GE supplied six stage power turbine stage 1 nozzle, and stages 1 and 6 rotor blades. For two stage power turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title

For LM2500+ Models GK and GV gas generators, Models PK and PV gas turbines, and GE supplied six stage power turbine: Operation and Maintenance Manual, Volume I GEK 105054 Gas Turbine Assembly Description Chapter 4 Installation/Initial Startup and Engine Operation Chapter 7 Troubleshooting Chapter 9 Preventive Maintenance Chapter 11 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Igniter Plug and Ignition Lead Replacement WP 103 00 Thermocouple Probe (T5.4) and Harness Replacement WP 108 00 High Pressure Compressor Inlet Pressure/Temperature (P2/T2) Sensor Replacement WP 109 00 Power Turbine Inlet Pressure (P5.4) Probe Replacement WP 112 00 Gas Generator Outside Piping and Wiring Removal and Installation WP 113 00 Gas Turbine Outside Piping and Wiring Removal and Installation SWP 113 01 Ultraviolet Flame Sensing System Components Replacement WP 118 00 Variable Stator Vane Servovalve Replacement WP 121 00 Turbine Mid Frame Replacement WP 200 00 High Pressure Turbine Stage 2 Nozzle Assembly Replacement SWP 201 01 High Pressure Turbine Stage 1 Nozzle Assembly Replacement SWP 201 02 High Pressure Turbine Rotor Blades Replacement WP 202 00 Single Annular Combustor Replacement WP 203 00 Gas Generator Inlet Duct Replacement WP 204 00 High Pressure Compressor Stator Casings Replacement WP 211 00 High Pressure Compressor Variable Stator Vane Replacement WP 212 00

2




For LM2500+ Models GK and GV gas generators, Models PK and PV gas turbines, and GE supplied six stage power turbine: - (cont.) High Pressure Compressor Fixed Stator Vane Replacement WP 214 00 High Pressure Compressor Rotor Blades Replacement WP 215 00 Gas Turbine Miscellaneous Sump Components Replacement SWP 217 01 Six Stage Power Turbine Stage 1 Rotor Blade Replacement WP 219 00 Gas Generator Assembly Replacement WP 301 00 Power Turbine Assembly Replacement WP 302 00 Water-Wash WP 405 00 Fuel System Inspection WP 415 00 High Pressure Turbine Stage 1 Nozzle Inspection WP 427 00 High Pressure Turbine Stage 2 Nozzle Inspection WP 428 00 Illustrated Parts Breakdown GEK 105055 For two stage power turbine: Operations and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

4.


Part No.

Assembly, Hydraulic Actuator Unit Spline, Adapter, Manual or Front Drive Pad Drive Motor, Electric Drive Motor, Electric Borescope, Rigid Borescope, Flexible

1C3569G2/G3 1C8208G02 2C14764G05 2C14764G06 2C6388G06 856A1321



Antiseize Compound

Milk of Magnesia (Unflavored) MIL-L-23699 or MIL-L-7808

Lubricating Oil 5.


IPB Figure No./Item

Preformed Packing

8-153


3

GEK 105054 Volume II WP 406 00 6.


Engine Preparation for Borescope Inspection. a.

Comply with WP 002 00.

b.

Remove external piping and wiring, as required to perform borescope inspection, per WP 113 00 or SWP 113 01.

c.

Remove components, as required to perform borescope inspection, per table 1 or per packager’s manual. Cover ports with appropriate material when not in use.

d.

Install adapter plate, 1C8208P05, onto accessory gearbox as follows: (1)

Remove nuts and washers that secure aft maintenance drive pad cover. See Volume I, Chapter 4, Figure 4-21.

(2)

Remove aft maintenance drive pad cover and discard preformed packing. WARNING


Using nuts, secure adapter plate, 1C8208P05, onto aft maintenance drive pad. Tighten nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque. Table 1. Component Removal Work Packages for Borescope Inspection

Component

4

Work Package

Inspect

T5.4 Probe

WP 108 00

High pressure turbine (HPT) stage 2 rotor blades and nozzle, turbine mid frame (TMF) liner, power turbine stage 1 nozzle and stage 1 rotor blades

P2/T2

WP 109 00

Inlet guide vanes (IGV)

P5.4 Probe

WP 112 00

Same as T5.4 probes

Igniter

WP 103 00

Combustor, fuel nozzles and HPT stage 1 nozzle

Flame Detector Sigh Glass

WP 118 00

Combustor, fuel nozzles and HPT stage 1 nozzle




Install electric drive motor, 2C14764, onto accessory gearbox and adapter plate, 1C8208P05, as follows: (1)

Align square drive of electric drive motor, 2C14764, with drive shaft, 1C8208P06, and secure with setscrew. Tighten setscrew hand-tight. Using lubricating oil, lubricate drive shaft spline.

(2)

Using washers and bolts, secure electric drive motor, 2C14764, to adapter plate, 1C8208P05, on accessory gearbox aft maintenance drive pad while ensuring proper alignment of splines of drive shaft, 1C8208P06, and gearbox. Tighten bolts to 420-510 lb in. (47.5-57.6 N⋅m) of torque.

(3)

Connect electric drive motor, 2C14764, to applicable power source. WARNING

•

DO NOT LOOK DIRECTLY INTO LIGHT OUTLET PORT OF BORESCOPE. HIGH INTENSITY LIGHT WILL CAUSE A MOMENTARY LOSS OF EYESIGHT AND COULD RESULT IN PERMANENT EYE DAMAGE.

•

IMPROPERLY GROUNDED BORESCOPE LIGHT SOURCE COULD CAUSE SEVERE SHOCK OR DEATH. EQUIPMENT SHALL BE PROPERLY GROUNDED BEFORE USE.

•

TO MAINTAIN EXPLOSION PROTECTION, DO NOT OPERATE BORESCOPE IF LAMP MODULE PRESSURE IS NOT WITHIN SPECIFIED LIMITS.

•

THE BORESCOPE LIGHT SOURCE CAN CAUSE AN EXPLOSION IF EXPOSED TO EXPLOSIVE VAPORS. DURING OPERATION, IT SHALL BE POSITIONED AT LEAST 18 INCHES ABOVE THE FLOOR. CAUTION

DO NOT PERFORM BORESCOPE INSPECTION IF TEMPERATURE INSIDE ENGINE IS ABOVE 150°F (65°C), OR DAMAGE TO BORESCOPE EQUIPMENT WILL OCCUR. f.

Prepare borescope set (figure 1) for use as follows: NOTE Use of either rigid borescope, 2C6388, or flexible borescope, 856A1321, is allowed. (1)

Select appropriate probe.

(2)

Connect cable to probe and light source.


5



Figure 1. Borescope Set Assembly-Typical (Sheet 1 of 2) 6




Figure 1. Borescope Set Assembly-Typical (Sheet 2 of 2) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

7



BEFORE CONNECTING LIGHT SOURCE TO POWER SOURCE, ENSURE THAT ON-OFF SWITCH IS IN OFF POSITION. (3)

Connect light source to grounded power source.

(4)

If necessary, attach magnification adapter to probe eyepiece. Focus probe before attaching magnification adapter.

(5)

If film records are necessary, attach optional recording equipment as follows: (a) If photographs are to be taken, attach camera adapter to 35 mm camera. Attach camera and adapter to eyepiece on probe. (b) If movie/video is to be taken, attach television adapter to television/video camera. Attach adapter and camera to eyepiece.

(6)

If desired, attach 60 or 90 degree angle adapter to probe eyepiece.

(7)

Adjust light intensity through probe as follows: (a) Move power switch on the light source to ON position. NOTE

Photo arc light circuit has thermal delay cutout that prevents light source from being turned on if it is too hot. (b) After inserting probe in engine borescope port, adjust light intensity to get correct illumination. 7.

Definitions. a.

The following definitions are provided for use in noting conditions during borescope inspection: (1)

Cracks or Torn Metal: (a) Cracks and torn metal (figure 2) have sharp edge at crack front, which is advancing edge of crack or tear. (b) Crack is a separation of parent material. (c) Coating cracks may be serviceable, see Table for inspection criteria at any depth of any blade or vane.

8




Figure 2. Compressor Blade and Vane Damage Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

9

GEK 105054 Volume II WP 406 00 (2)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Dents: (a) Depressions in surface, typically not on leading or trailing edge. (b) Depth is measured from original location of metal. (c) Radius shall not be less than 0.010 inch (0.26 mm).

(3)

Crush/Nick: (a) Crush type deformation is chordwise depression on blade or vane leading or trailing edge with metal protruding above airfoil surface on both concave and convex side. (b) No metal may be torn or missing.

(4)

Chip: (a) Removal of metal or coating from component. (b) Critical parameters of chip are depth, measured from edge, and radius, measured at bottom (root) of chip.

(5)

Tip Curl: (a) Can be on leading or trailing edge. (b) Critical parameter of tip curl is curled length of tip chord. (c) Maximum of 25 percent of tip chord is allowed to be curled, if:

10

1

It does not engage stationary parts during operation.

2

There is no other blade distortion caused by damage.

3

There is no torn metal.




Borescope Inspection. a.

If inspecting HPC rotor components, actuate variable stator vanes (VSV) to full open position as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. NOTE VSV actuators may be operated using clean, dry shop air, regulated, dry nitrogen, or engine lubricating oil. (1)

Disconnect rod-end and head-end hoses at VSV servovalve. Drain residual oil into approved waste container. CAUTION

•


•


•


(2)

Connect pressure source to VSV actuator rod-end hose.

(3)

Place approved waste container under head-end hose to catch residual oil. WARNING

SERIOUS INJURY CAN OCCUR WHEN APPLYING PRESSURE. EYE PROTECTION IS REQUIRED, RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS.

b.

(4)

Supply pressure to VSV actuator. Use maximum of 200 psig (1,378 kPa).

(5)

Position VSV to full open position.

Inspect engine inlet guide vane shrouds and bushings as follows. A flexible borescope (MSE -76) is required for this inspection: (1)

Remove inlet duct and screen per WP 204 00.


11

GEK 105054 Volume II WP 406 00 (2)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Inspect IGV shrouds and bushings (figure 3) as follows: (a) Using suitable probe, locate gap at aft side of IGV inner shroud. (b) Deflect probe tip down toward engine centerline. (c) Position probe tip in gap to view aft side of shroud. (d) Using probe tip articulation, rotate probe body to change viewing direction along back surface of shroud. NOTE

Wear on IGV shroud will not likely occur without wear on stages 0, 1, and 2 shrouds. (e) Inspect components per table 2 and record conditions. (f) Remove probe. (3)

After inspection, proceed as follows: (a) If inspection reveals no wear, comply with GEK 105054, Chapter 11, table 11-1. (b) If inspection reveals slight wear, reinspect every 2,500 hours of operation or first opportunity thereafter. (c) If inspection reveals excessive wear, replace hardware per the appropriate Work Package. Following replacement, begin inspection period per GEK 105054, Chapter 11, table 11-1. CAUTION

IF HANG-UP OCCURS, FREE PROBE BY GENTLE MOVEMENTS, AS EXCESSIVE FORCE COULD DAMAGE BORESCOPE.

12

(4)

Repeat step (2) at eight equally spaced locations around shroud. Record conditions observed.

(5)

Repeat steps (2) through (4) for stages 0, 1, and 2 shrouds, except Table 2, item (f) only applies to IGV.

(6)

After close visual inspection with borescope, manually move vanes (IGV and stages 0 and 1, if possible) and check for any excessive play between vane platform and shroud.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Categories of Bushing Wear Conditions No Wear

Slight Wear

Excessive Wear

a. Shrouds slightly dirty

a. Shrouds very dirty

a. Evidence of vane trailing edge rub on aft OD of shroud

b. No protrusion of bushing material

b. Slight protrusion of bushing material

b. Cracks or holes worn through shroud side

c. No evidence of vane trailing edge rub on aft OD of shroud

c. No evidence of vane trailing edge rub on aft OD of shroud

c. Bushing material protruding from shroud

d. No cracks or bulges on shroud sides

d. No cracks or bulges on shroud sides

d. Aft movement of vane platform to extend beyond the recess in the upper surface

e. No aft movement of vane platform in shroud

e. Small amount of aft movement of vane platform

e. Excessive amount of aft movement of vane platform

Figure 3. VSV Shrouds and Bushings Inspection


13



c.

•

TO PREVENT FOREIGN OBJECTS FROM ENTERING ENGINE, KEEP BORESCOPE PORTS COVERED WHEN THEY ARE NOT BEING USED. OPEN ONE PORT AT A TIME.

•

DO NOT PERFORM BORESCOPE INSPECTION IF TEMPERATURE INSIDE ENGINE IS ABOVE 150°F (65°C), OR DAMAGE TO BORESCOPE EQUIPMENT WILL OCCUR.

Inspect HPC rotor and stator vanes as follows: NOTE Zero indexing of gas generator rotor is required to determine when rotor has completed one revolution during inspection of HPC rotor blades or HPT rotor blades. (1)

Zero index gas generator rotor as follows: (a) Remove plug from stage 10 borescope port (12, figure 4). (b) Insert probe into stage 10 borescope port (12), look aft, and observe stage 11 rotor blade platforms. CAUTION

WHEN ROTATING HPC ROTOR, ENSURE BORESCOPE PROBE IS IN SAFE POSITION, OR DAMAGE TO ENGINE OR BORESCOPE WILL RESULT. (c) Rotate rotor counterclockwise (CCW) until first rotor blade slot locking lug (figure 5) is visible. (d) Continue to rotate CCW until second locking lug appears, normally two blades past first locking lug. (e) Position next rotor blade CCW from second locking lug so leading edge is in line with leading edge of stage 11 compressor stator vane. (f) Count blades in rotation from zero and record blade numbers with defects in amount and size. Record inspection data.

14




Figure 4. Borescope Port Locations (Sheet 1 of 2) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

15



Figure 4. Borescope Port Locations (Sheet 2 of 2)

Figure 5. Zero Indexing of HPC Rotor and HPT Rotor 16




TO PREVENT FOREIGN OBJECTS FROM ENTERING ENGINE, KEEP BORESCOPE PORTS COVERED WHEN THEY ARE NOT BEING USED. OPEN ONE PORT AT A TIME. (2)

If present, remove safety wire from borescope plug.

(3)

Remove borescope plug from borescope port per table 3 and figure 4. Some locations require removal of manifold piping to access plugs inside the manifold. Table 3. HPC Borescope Inspection Locations

No.

Port Location

Engine Inlet

Parts Viewed

Plug Torque

IGV’s

2

HPC stage 0

HPC stages 0 and 1 rotor blades, 2 stage 0 stator vanes

40-60 lb in. (4.5-6.7 N⋅m)

3

HPC stage 1


40-60 lb in. (4.5-6.7 N⋅m)

4

HPC stage 2

HPC stages 2 and 3 rotor blades, 2 stage 2 stator vane

40-60 lb in. (4.5-6.7 N⋅m)

5

HPC stage 3


40-60 lb in. (4.5-6.7 N⋅m)

6

HPC stage 4


40-60 lb in. (4.5-6.7 N⋅m)

7

HPC stage 5


40-60 lb in. (4.5-6.7 N⋅m)

8

HPC stage 6


40-60 lb in. (4.5-6.7 N⋅m)

9

HPC stage 7


40-60 lb in. (4.5-6.7 N⋅m)

10

HPC stage 8


40-60 lb in. (4.5-6.7 N⋅m)


17


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. HPC Borescope Inspection Locations - (Cont.)

No.

Port Location

Parts Viewed

Plug Torque

11

HPC stage 9


40-60 lb in. (4.5-6.7 N⋅m)

12

HPC stage 10


40-60 lb in. (4.5-6.7 N⋅m)

13

HPC stage 11

HPC stages 11 and 12 rotor blades, 2 stage 11 compressor vanes

40-60 lb in. (4.5-6.7 N⋅m)

14

HPC stage 12


80-100 lb in. (9.0-11.2 N⋅m) (metal O-ring under plug)

15

HPC stage 14 (Inside Manifold)



16

HPC stage 15



(4)

Use borescope to inspect HPC rotor blades and stator vanes as follows: (a) Two stator vanes in each stage adjacent to borescope port may be inspected. CAUTION

WHEN ROTATING HPC ROTOR, ENSURE BORESCOPE PROBE IS IN SAFE POSITION, OR DAMAGE TO ENGINE OR BORESCOPE WILL RESULT. (b) Inspect all HPC rotor blades by rotating HPC rotor. (c) Inspect HPC rotor blades and stator vanes per table 4.

18



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. HPC Blades and Vanes Inspect


1. Stage 0 Blisk: (figure 6) a. Cracks Not serviceable b.

General damage on airfoil, concave/ convex surfaces:

c.

Leading and trailing edge damage

d.

Blade tips for: (1) Tip curl



Not repairable


Any amount, if damage does not form line transverse to airfoil that may crack in subsequent operation; damage is 0.50 in. (12.7 mm) from leading or trailing edge; damage does not break through (protrusion acceptable); damage is less than 0.095 in. (2.41 mm) in diameter Judge acceptability by sharpness of damage. Sharp or torn edges are not serviceable

Not repairable

Not repairable


25 percent of chord, if it does not engage stationary parts during operation, there is no blade distortion caused by damage, and there are no tears in airfoil 2. Stages 1 through 16 Blades for: (figure 7) a. Cracks Not serviceable

Not repairable


Not repairable

Inspect and replace blades per WP 215 00


19


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. HPC Blades and Vanes- (Cont.)

Inspect



2. Stages 1 through 16 Blades for: - (cont.) b. General Any amount, if Not repairable damage on damage does not airfoil, form line transverse concave/ to airfoil that may convex crack in subsequent surfaces: operation; damage is 0.50 in. (12.7 mm) from leading or trailing edge; damage does not break through (protrusion acceptable); damage is less than 0.095 in. (2.41 mm) in diameter c. Leading and Judge acceptability Not repairable trailing edge by sharpness of damage damage. Sharp or torn edges are not serviceable d. Blade tips for: (1) Tip curl 25 percent of chord, if Not repairable it does not engage stationary parts during operation, there is no blade distortion caused by damage, and there are no tears in airfoil (2) Tip trailing edge for missing pieces: (figure 8) (a) Stages Max of six per stage, Not repairable 1-9 if all downstream damage is serviceable. Max size of any missing piece is 1/3 chord by 1/3 span

20








LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. HPC Blades and Vanes- (Cont.) Inspect




2. Stages 1 through 16 Blades for: - (cont.) (b)

e.

Stages 10-16

Aluminum or abrasive deposits on blades (leading edge especially)

Max of 10 per stage, if all downstream damage is serviceable. Max size of any missing piece is 1/3 chord by 1/3 span Any amount, unless compressor stall occurs

Not repairable

See Corrective Action Column


Troubleshoot for stalls/high vibrations as required, per GEK 105054 Chapter 9

NOTE Tip clanging contact occurs when blade vibration causes contact between leading edge tip of one blade and convex side of adjacent blade. It often indicates that compressor underwent severe compressor stall. f.

Tip clanging contact stages 3-6 (figure 9)

Not serviceable

Not repairable


3. HPC Rotor and Stator Airflow Path Surfaces for: a.

Corrosion, dirt, or oil on air flow path surfaces

Any amount


Water-wash HPC per WP 405 00

b.

Abrasive coating missing from rotor or stator case

Any amount


Troubleshoot for stalls/high vibrations, as required, per GEK 105054 Chapter 9


21


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. HPC Blades and Vanes- (Cont.)

Inspect




4. Stator Vanes for: NOTE It may be necessary to use flexible borescope or remove HPC stator top casing per WP 211 00 to assess total damage.

22

a.

Cracked or torn material

Not serviceable

Not repairable

Replace vanes per WP 212 00 for IGV-stage 6, WP 214 00 for stages 7-15

b.

General damage (peppering)all stages

Any amount up to 0.015 in. (0.38 mm) deep, if vane is not cracked, damage does not break through, and vane is not distorted. None allowed in fillets

Not repairable


c.

Nicks and scratches-all stages

Any number, 0.015 in. (0.38 mm) deep, 0.50 in. (12.7 mm) long, with min. separation of 0.063 in. (1.60 mm). None allowed in transverse direction

Not repairable


d.

Dents-IGV through stage 11

0.047 in. (1.19 mm) deep, if damage is of smooth contour and does not form crease

Not repairable


e.

Tip curl - all vanes

24 percent of chord length, if it does not engage rotating parts during operation and there is no other distortion

Not repairable





Figure 6. HPC Stage 0 (Blisk)

Figure 7. Compressor Rotor Blades Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

23



Figure 8. Tip Trailing Edge Inspection

Figure 9. Tip Clanging Contact (Rotor Stages 3 through 6)

24




Inspect combustor, fuel nozzles, HPT assembly, and TMF as follows: CAUTION

•


•

DO NOT PERFORM BORESCOPE INSPECTION IF TEMPERATURE INSIDE ENGINE IS ABOVE 150°F (65°C) OR DAMAGE TO BORESCOPE EQUIPMENT WILL OCCUR.

(1)

If present, remove safety wire from borescope plug.

(2)

Remove borescope plug from borescope port per table 5 and figure 4.

(3)

Use borescope to inspect combustor and fuel nozzles per table 6 and figure 10. Figure 10 includes only a representative view of fuel nozzle, for additional specific fuel nozzle inspection criteria, see WP 415 00.

(4)

Use borescope to inspect HPT as follows: NOTE

•

HPC rotor and HPT rotor are joined mechanically. Zero indexing of HPC rotor will perform same function for HPT rotor.

•

HPT rotor has 88 stage 1 blades and 90 stage 2 blades. (a) Zero index HPT rotor per step c. (1). CAUTION

WHEN ROTATING HPC ROTOR, ENSURE BORESCOPE PROBE IS IN SAFE POSITION, OR DAMAGE TO ENGINE OR BORESCOPE WILL RESULT. (b) Inspect all HPT rotor blades by rotating HPC rotor. (c) Inspect HPT rotor blades and nozzles per table 7 and figure 10. (5)

Use borescope to inspect TMF per table 8 and figure 10.


25



Table 5. CRF, Combustor, Fuel Nozzle, and HPT Borescope Inspection Locations No.

Port Location

Parts Viewed

17 (A-F)

CRF, 6 ports

Combustor, fuel nozzles, and HPT stage 1 blades and nozzle

18

CRF port

HPT stage 1 blades and nozzle

19

CRF port

HPT stages 1 and 2 blades; HPT stage 2 nozzle

20 (A, B, C, D, E, F, G, H, and I)

T5.4 and P5.4 probe ports

HPT stage 2 blades; power turbine stage 1 blades and nozzle, TMF liner

Plug Torque 140-160 lb in. (15.8-18.0 N⋅m) (washer under plug) 300-325 lb in. (33.9-36.7 N⋅m) (washer under plug) 200-225 lb in. (22.6-25.4 N⋅m) (washer under plug) 35-40 lb in. (4.0-4.5 N⋅m) (probe nut)

Table 6. Single Annular Combustor Inspection Inspect 1. All Surfaces for: a. Discoloration b. Carbon accumulation 2. Riveted Joints for: a. Loose, cracked, or missing rivets



Serviceable Any amount

Six nonadjacent rivets in each rivet circle may be loose, cracked, or missing b. Cracked or One crack 0.030 in. torn rivet (0.76 mm) long per holes in cowl hole; 20 holes max and skirts per rivet circle 3. Dome Band and Dome Plate (Excluding Overhung Surfaces) for: a. Axial cracks Any number less than 1.25 in. (31.7 mm) long; one crack greater than 1.25 in. (31.7 mm) in each swirl cup location, max length of 2.25 in. (57.1 mm) not to exceed eight per dome

26

On-Site Corrective Limits

Replace combustor per WP 203 00*





LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Single Annular Combustor Inspection - (Cont.) Inspect




3. Dome Band and Dome Plate (Excluding Overhung Surfaces) for: - (cont.) b.

Circumferential cracks

Any number less than 0.75 in. (19.0 mm) long, five cracks 2.25 in. (57.1 mm) long separated by 1.00 in. (25.4 mm) from any other crack greater than 0.75 in. (19.0 mm) long


4. Trumpet and Swirl Cup (Excluding Overhung Surfaces) for: a.

Cracks

Four cracks, 1.25 in. (31.7 mm) long per item; any number less than 0.50 in. (12.7 mm) long

b.

Distortion of trumpet

Any amount


5. Dome Assembly (Dome Band, Dome-Plate, Trumpet, and Swirl Cup) for: a.

Burn through or missing metal of nonoverhung surfaces

Any amount less than 90 degrees maximum burn through of domeplate around any one swirl cup. Burn through limited to eight areas per dome, maximum size 1.00 in. (25.4 mm) by 1.00 in. (25.4 mm). Any amount of trumpet distress is allowed



27


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Single Annular Combustor Inspection - (Cont.)

Inspect




5. Dome Assembly (Dome Band, Dome-Plate, Trumpet, and Swirl Cup) for: - (Cont.) NOTE Burn through in combustor dome will reduce the cooling flow to the HPT nozzles vanes. Inspect the HPT vanes per WP 427 00 and WP 428 00. a.

Burn through or missing metal of overhung surfaces.

Any amount

6. Igniter ferrule for: a.

Cracks

Any number 0.25 in. (6.3 mm) long


b.

Burns

0.13 in. (3.3 mm) burn permissible on bottom of ferrule (flame side)


c.

Wear

0.75 in. (19.0 mm) inside diameter (ID) max


7. Inner and Outer Liners for: a.

28


Any number noninterconnecting cracks per band, each 1.00 in. (25.4 mm) long separated by 2.00 in. (50.8 mm) from any other crack. Total length of all circumferential cracks in any band shall not exceed 7.00 in. (177.8 mm)




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Single Annular Combustor Inspection - (Cont.)

Inspect




7. Inner and Outer Liners for: - (cont.) b.

Axial cracks

Six cracks per liner, max length not to exceed 2 adjoining bands (3 rows of cooling holes), any number of cracks 1.25 in. (31.7 mm) per band. Axial and circumferential cracks, 1.00 in. (25.4 mm) or longer shall have minimum separation of 2.00 in. (50.8 mm)


c.

Burns

Six burned through areas of 0.75 in. (19.0 mm) by 1.00 in. (25.4 mm) per liner separated by 2.50 in. (63.5 mm)


d.

Distortion

Any amount within 0.50 in. (12.7 mm) from original contour


Accept three burn through areas of 0.25 in. (6.3 mm) by 1.00 in. (25.4 mm)


8. Cowl for: a.

Burns at fuel nozzle eyelet (fuel nozzle removed)

b.

Cracks

Any number 0.25 in. (6.3 mm) long * May be repairable, consult GE for disposition or replace parts.



29



Figure 10. Single Annular Combustor Inspection (Sheet 1 of 3) 30




Figure 10. Single Annular Combustor Inspection (Sheet 2 of 3) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

31



Figure 10. Single Annular Combustor Inspection (Sheet 3 of 3) 32



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. HPT Borescope Inspection

Inspect




1. HPT Stage 1 Nozzle Vane Airfoil for: (figure 11) a.

Axial cracks in trailing edge (concave side)

One per slot, 0.31 in. (7.8 mm) long, or two per vane, 0.75 in. (19.0 mm) long, if cracks are 0.31 in. (7.8 mm) apart. A 1.50 in. (38.1 mm) long crack cannot extend axially beyond first row of gill holes

Not repairable

Replace HPT stage 1 nozzle or nozzle segment per SWP 201 02

NOTE To assist in visually gauging observed defects by comparison, the center-to-center dimension between nose or gill holes in any given row (radial direction) is approximately 0.06 inch (1.5 mm). b.

Axial cracks in leading edge

Any number, 0.50 in. (12.7 mm) long separated by 0.25 in. (6.3 mm), or any number of cracks interconnecting cooling holes, if total length of interconnecting cracks do not exceed six gill holes. Cracks extending aft of gill holes on convex side are not allowed

Not repairable



33


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. HPT Borescope Inspection - (Cont.)

Inspect




1. HPT Stage 1 Nozzle Vane Airfoil for: - (cont.)

34

c.

Radial cracks in concave surface between inner and outer platforms

Any number, 0.50 in. (12.7 mm) long, or two per vane, 0.75 in. (19.0 mm) long, if cracks are 0.31 in. (7.8 mm) apart

Not repairable


d.

Radial cracks in convex surfaces between inner and outer platforms

One crack allowed 0.75 in. (19.0 mm) long

Not repairable


e.

Buckling or bowing of trailing edge

Any number, 0.31 in. (7.8 mm) from original contour

Not repairable


f.

Axial cracks in concave surface

Two cracks per vane extending aft from aft row of gill holes to (not through) slot in trailing edge

Not repairable


g.

Corrosion, burns, and cracks on concave and convex sides including trailing edge

Not to exceed an area of 1.20 in. (30.4 mm) long and 1.00 in. (25.4 mm) wide per vane, max of four vanes per 90 degree arc. Missing metal in inserts (inner liner) not allowed

Not repairable


h.

Burns or spalling on vane leading edge

0.50 in. (12.7 mm) diameter per vane, max of four vanes affected per 90 degree arc. No missing metal in inserts allowed

Not repairable





Inspect




1. HPT Stage 1 Nozzle Vane Airfoil for: - (cont.) NOTE Craze cracking is defined as numerous superficial surface cracks which have no visual width or depth. i.

Craze cracking

Any amount

-

-

j.

Nicks, scores, scratches

Any number, any length, 0.031 in. (0.78 mm) deep

Not repairable


k.

Bulging, bowing, or dents

0.125 in. (3.17 mm) out of original contour. Max of three vanes affected per 90 degree arc

Not repairable


2. HPT Stage 1 Nozzle Inner and Outer Platform for: a.

Cracks in welds between vanes

2/3 length of weld at outer platform, if weld at inner platform has no cracks, or 1/3 length of original weld, if inner platform has crack of any length

Not repairable


b.

Cracks in parent metal

Any number, 0.875 in. (22.22 mm) long

Not repairable


c.

Nicks, scores, scratches, and dents on platform surface

Any number, 0.063 in. (1.60 mm) deep

Not repairable



35



Inspect




2. HPT Stage 1 Nozzle Inner and Outer Platform for: - (cont.) d.

Corrosion, erosion, and burns on vane platform

0.50 in. (12.7 mm) wide, any length, max of six vanes per 90 degrees. Burn through allowed, 0.125 in. (3.18 mm) wide by 0.50 in. (12.7 mm) length, two per 90 degrees, not in same nozzle segment

Not repairable


e.

Corrosion, erosion, and burns on inner platform trailing edge (loss of metal)

Six vanes per 90 degrees arc, 0.25 in. (6.4 mm) two per vane

Not repairable


f.

Displacement of intersegment seals from groove (see figure 10A)

Any number

-

-

3. HPT Stage 2 Nozzle Vane Airfoil for: (figure 12)

36

a.

Axial cracks in trailing edge

Any number, 0.09 in. (2.3 mm) long, two per vane, 0.50 in. (12.7 mm) long, if cracks are 0.25 in. (6.4 mm) apart

Not repairable


b.

Axial cracks in leading edge

Not serviceable

Not repairable


c.

Cracks in concave surfaces

Two cracks, 1.50 in. (38.1 mm) max length

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. HPT Borescope Inspection - (Cont.) Inspect




3. HPT Stage 2 Nozzle Vane Airfoil for: - (cont.) NOTE

d. e.

f.

g.

h.

i.

Craze cracking is defined as numerous superficial cracks which have no visual width or depth. Craze cracking Any amount Buckling of trail- Any amount, Not repairable ing edge 0.06 in. (1.5 mm) from original contour Burns on 1.0 in2 (6.5 cm2) area Not repairable airfoil surfaces with no through holes Corrosion

Any amount, if Not repairable corrosion is not completely through metal thickness Nicks, scores, Any number, 0.25 in. Not repairable scratches, or (6.4 mm) long, dents 0.03 in. (0.8 mm) deep, after removal of high metal Buckling of trail- 0.06 in. (1.5 mm) Not repairable ing edge from original contour

j.

Eroded areas

Any amount, 0.02 in. Not repairable (0.5 mm) deep

k.

Corrosion, burns, and material missing from trailing edge

Not to exceed area of Not repairable 1.2 inches (30 mm) long and 1.0 inch (25 mm) wide per vane, maximum four vanes per 90 degree arc. Missing metal in inserts not allowed

Replace HPT stage 2 nozzle or nozzle segment per SWP 201 01 Replace HPT stage 2 nozzle or nozzle segment per SWP 201 01 Replace HPT stage 2 nozzle or nozzle segment per SWP 201 01 Replace HPT stage 2 nozzle or nozzle segment per SWP 201 01

Replace HPT stage 2 nozzle or nozzle segment per SWP 201 01 Replace HPT stage 2 nozzle or nozzle segment per SWP 201 01 Replace HPT stage 2 nozzle or nozzle segment per SWP 201 01


37

GEK 105054 Volume II WP 406 00 Inspect


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines On-Site Maximum On-Site Corrective Repairable Limits Action

4. HPT Stage 2 Nozzle Inner and Outer Platform for: a. Cracks Any number, 0.63 in. Not repairable Replace HPT stage 2 between vanes (16.0 mm) long sepanozzle or nozzle segrated by 0.25 in. ment per (6.4 mm) SWP 201 01 NOTE Craze cracking is defined as numerous superficial cracks which have no visual width or depth. b. Craze cracking Any amount c.

Cracks in outer band trailing edge

d.

Two cracks, 0.38 in. (9.7 mm) long. Any number, 0.13 in. (3.3 mm) long Any number

Not repairable

Displacement of intersegment seals from groove (figure 10B) 5. HPT Stages 1 and 2 Nozzle Shroud for: a. Wear Any amount, if back- Not repairable ing strip is not damaged

38

b.

Erosion

c.

Axial cracks

d.

Distortion

Not repairable Total eroded area missing not to exceed 10 percent, if missing area is not completely across axial width of shroud; no single area to exceed 1.00 in2 (6.5 cm2) Two per shroud Not repairable segment, 0.25 in. (6.4 mm) long. One per shroud segment, 1.00 in. (25.4 mm) long Free state Not repairable distortion allowable, if proper assembly and blade clearance can be maintained

Replace HPT stage 2 nozzle or nozzle segment per SWP 201 01 -

Replace HPT nozzle shroud per SWP 201 01 or SWP 201 02 Replace HPT nozzle shroud per SWP 201 01 or SWP 201 02

Replace HPT nozzle shroud per SWP 201 01 or SWP 201 02

Replace HPT nozzle shroud per SWP 201 01 or SWP 201 02




Inspect




6. HPT Rotor Blades-Leading Edge Area A for: (figure 13) NOTE

• Blades have platinum aluminided overlay coating which is 0.00150.004 inch (0.038-0.10 mm) thick.

•

During inspection of blades, visual evidence of plugged cooling holes is not positive. Evidence of plugged cooling holes is acceptable if crack, erosion, and burning limits are serviceable.

a.

Cracks propagating from nose holes (Stage 1)

Any number, if cracks do not extend into gill holes

Not repairable

Replace HPT rotor blade per WP 202 00

b.

Cracks propagating from gill holes (Stage 1)

Any number, on convex side, if cracks do not extend into nose holes

Not repairable


c.

Erosion and burning

Any amount, to gill holes, if radial cooling passage is not exposed

Not repairable


d.

Nicks and dents

Any amount, if damage does not extend past gill holes and there is no torn metal or cracks

Not repairable


e.

Tears

Not serviceable

Not repairable


f.

Axial cracks (Stage 2)

Not serviceable

Not repairable



39



Inspect




7. HPT Rotor Blades-Leading Edge Area B for:

40

a.

Cracks propagating from gill holes (Stage 1)

No cracks allowed

Not repairable


b.

Radial cracks out of leading edge holes (Stage 1)

Any number, if cracks do not connect two holes and do not turn in axial direction

Not repairable


c.

Erosion and burning

Any amount, if not through coating. If coating is penetrated, gas generator shall be replaced within 1,800 hours and borescope inspected at 600 hour intervals prior to replacement

Not repairable


d.

Axial cracks out of leading edge holes

Not serviceable

Not repairable


e.

Nicks and dents

Not serviceable

Not repairable





Inspect




8. HPT Rotor Blade Tips for: a.

Tip cracks

Any number of radial cracks, 0.65 in. (16.5 mm) long. One axial crack, 0.50 in. (12.7 mm) long, if crack does not extend below tip metering cap

Not repairable


b.

Bent or curled blade tips

Two areas, 0.25 in. (6.3 mm) long

Not repairable


c.

Dents in leading edge of blade tip

Any depth, if metal is not torn

Not repairable


d.

Missing pieces (missing pieces refers to blade base metal loss, not localized coating)

Any amount of material missing above the tip cap lip

Not repairable


e.

Tip wear

Acceptable down to top of tip cap

Not repairable



41



Inspect




8. HPT Rotor Blade Tips for: - (cont.) f.

Tip burning

Any amount, if blade internal cooling passages are not exposed

Not repairable


9. HPT Rotor Blade-Trailing Edge Area A for:

42

a.

Cracks

Not serviceable

Not repairable


b.

Clogged air passages (Stage 1)

Top hole, plus three additional holes in any area above bottom eight holes, if no two are adjacent

Not repairable


c.

Erosion and corrosion in area of hot spots

Any amount, if cooling holes are not penetrated from either concave or convex walls

Not repairable


d.

Nicks and dents

Any amount, if there is no torn metal or cracks

Not repairable


e.

Tears

Not serviceable

Not repairable





Inspect




10. HPT Rotor Blade-Trailing Edge Area B for: a.

Cracks

Not serviceable

Not repairable


b.

Clogged air passages (Stage 1)

Not serviceable

Not repairable


c.

Erosion and corrosion in area of hot spots

If coating is penetrated, gas generator shall be replaced within 1,800 hours and borescope inspected at 600 hour intervals prior to replacement

Not repairable


d.

Nicks and dents

Not serviceable

Not repairable


11. HPT Rotor Blade-Concave Surface Area A for: a.

Axial cracks

Any number of cracks in Area A with length up to half the distance between concave gill holes and trailing edge, if cracks do not connect with gill holes or trailing edge

Not repairable



43



Inspect




11. HPT Rotor Blade-Concave Surface Area A for: - (cont.)

44

b.

Coating craze cracks

Craze cracks are tight, multiple, and multidirectional coating cracks. Any number of craze cracks at any location on airfoil or platform

Not repairable


c.

Blocked gill holes (Stage 1)

Top gill hole plus one additional hole per row, not within 0.25 in. (6.3 mm) of root

Not repairable





Figure 10A. Stage 1 HPT Nozzle Seal Displacement Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

45



Figure 10B. Stage 2 HPT Nozzle Seal Displacement

46




Figure 11. HPT Stage 1 Nozzle Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

47



Figure 12. HPT Stage 2 Nozzle 48




Figure 13. HPT Rotor Blades Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

49


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 8. TMF Borescope Inspection

Inspect




1. Liner for: a.


Any number, not exceeding 2.00 in. (50.8 mm) length, and not joining with adjacent cracks. Monitor for propagation by borescope inspection at each opportunity, but not later than 500 hours of operation

Not repairable


b.

Missing material

Not serviceable

Not repairable


c.


Any amount, 0.25 in. (6.3 mm) from original contour

Not repairable


e.

Inspect power turbine as follows: CAUTION

•


•

DO NOT PERFORM BORESCOPE INSPECTION IF TEMPERATURE INSIDE ENGINE IS ABOVE 150°F (65°C), OR DAMAGE TO BORESCOPE EQUIPMENT WILL OCCUR.

(1)

Remove T5.4 thermocouple probes from TMF per WP 108 00.

(2)

Remove P5.4 pressure probe from TMF per WP 112 00.

(3)

Rotate power turbine rotor as follows: (a) If required, inspect via exhaust system per packager’s manual. (b) Manually rotate power turbine rotor per packager’s manual.

(4) 50

Use borescope to inspect power turbine per table 9. Change 1



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 9. Power Turbine Borescope Inspection - (Cont.)

Inspect




1. Power Turbine Stage 1 Nozzle-Outer and Inner Platforms for: (figure 14) a.

Cracks not in fillets


Not repairable

Replace power turbine stage 1 nozzle per SWP 217 01 or power turbine assembly per WP 302 00

b.

Nicks, dents, and scratches


Not repairable


2. Power Turbine Stage 1 Nozzle Airfoil Leading Edge for: a.

Cracks

Not serviceable

Not repairable


b.


0.06 in. (1.5 mm) deep, if no torn metal

Not repairable


c.

Corrosion and erosion

Any amount, if corrosion is not through vane

Not repairable



51



Inspect




3. Power Turbine Stage 1 Nozzle Airfoil Concave and Convex Surfaces Other than Edges for: - (cont.) a.

Cracks


Not repairable


b.


Any number, 0.031 in. (0.78 mm) deep, if no torn metal

Not repairable


c.


Any amount, if corrosion is not through vane

Not repairable


NOTE Power turbine rotor stages 2 through 5 blades are inaccessible to borescope inspection. 4. Power Turbine Rotor Stage 1 Blades-All Areas for: (figure 15) a.

Cracks

Not serviceable

Not repairable

Replace power turbine rotor stage 1 blades per WP 219 00

5. Power Turbine Rotor Stage 1 Blades-Leading and Trailing Edges for: a.

52

Nicks

None within 0.50 in. (12.7 mm) of inner platform or within 0.25 in. (6.3 mm) of shroud. Balance of blade any number, 0.04 in. (1.0 mm) deep, with min. separation of 0.50 in. (12.7 mm)

Not repairable





Inspect




5. Power Turbine Rotor Stage 1 Blades-Leading and Trailing Edges for: - (cont.) b.

Dents

Any number with no protrusions on opposite side, and five per blade with protrusion not to exceed 0.04 in. (1.0 mm) on opposite side

Not repairable


c.


Any amount

Not repairable


6. Power Turbine Rotor Blades Stage 1 Concave and Convex surfaces for: a.

Nicks

Any number, 0.04 in. (1.0 mm) deep, with min. separation of 0.25 in. (6.3 mm)

Not repairable


b.

Dents

Any number with no protrusion on opposite side

Not repairable


c.


Any amount

Not repairable


7. Circumferential mate faces on Power Turbine stage 1 shrouds (figure 16) for: a.

Wear (irregular or jagged)

Any amount, if there is no related interlock wear

Not repairable

Replace LPT module

8. Power Turbine Stage 1 blade shroud interlocks (figure 16) for: a.


Not serviceable

Not repairable

Replace LPT module

b.

Shingling or unlatching

Not serviceable

Not repairable

Replace LPT module


53



Inspect




9. Power Turbine Rotor Stage 6 Blades-All Areas for: a.

Cracks

Not serviceable

Not repairable


10. Power Turbine Rotor Stage 6 Blades-Leading and Trailing Edges for: a.

Nicks

None within 0.50 in. (12.7 mm) of inner platform, or within 0.25 in. (6.3 mm) of shroud. Balance of blade, any number 0.04 in. (1.0 mm) deep with min. separation of 0.50 in. (12.7 mm)

Not repairable

Replace power turbine assembly per WP 302 00

b.

Dents

Any number with no protrusions on opposite side, and five per blade with protrusion not to exceed 0.04 in. (1.0 mm) on opposite side

Not repairable


c.


Any amount

Not repairable


11. Power Turbine Rotor Stage 6 Blades-Concave and Convex Surfaces for:

54

a.

Nicks

Any number, 0.04 in. (1.0 mm) deep with min. separation of 0.25 in. (6.3 mm)

Not repairable


b.

Dents

Any number with no protrusions on opposite side

Not repairable


c.


Any amount

Not repairable





Inspect




12. Circumferential mate faces on Power Turbine stage 6 shrouds (figure 16) for: a.


Any amount, if there is no related interlock wear

Not repairable

Replace LPT module

13. Power Turbine Stage 6 blade shroud interlocks (figure 16) for: a.


Not serviceable

Not repairable

Replace LPT module

b.

Shingling or unlatching

Not serviceable

Not repairable

Replace LPT module


55



Figure 14. Power Turbine Nozzles

Figure 15. Power Turbine Rotor Blades 56



Figure 16.


LPT Rotor Blade Circumferential Inspection Change 1


57

GEK 105054 Volume II WP 406 00 9.


Engine Preparation for Operation. a.

Install removed engine components per table 1 and packager’s manual.

b.

Reinstall any removed piping, tubing, or wiring per WP 113 00 or SWP 113 01.

c.

If removed, reinstall inlet duct and screen per WP 204 00.

d.

If required, remove VSV pressure source as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (1)

Disconnect rod-end and head-end hoses from pressure source. Drain residual oil into approved waste container. CAUTION

DO NOT INTERMIX LUBRICATING OILS, MIL-L-7808 AND MIL-L-23699, OR VSV ACTUATOR FAILURE WILL OCCUR. (2) e.

58

Connect VSV rod-end and head-end hoses to VSV servovalve per WP 121 00.

Install borescope plugs as follows: (1)

Using antiseize compound, lubricate removed borescope plug threads.

(2)

Install removed borescope plugs into appropriate borescope ports.

(3)

Tighten borescope plugs per tables 3 and 5.

(4)

Safety-wire borescope plugs as required.

f.

If removed, install exhaust system per packager’s manual.

g.

Remove drive motor, 2C14764, drive shaft, 1C8208P06, and adapter plate, 1C8208P05, as follows: (1)

Remove bolts and washers that secure drive motor, 2C14764, to adapter plate, 1C8208P05, on aft maintenance drive pad of accessory gearbox. Remove drive motor.

(2)

Loosen setscrew that secures drive shaft, 1C8208P06, to square drive of electric drive motor, 2C14764. Remove drive shaft.

(3)

Remove nuts and washers that secure adapter plate, 1C8208P05, onto aft maintenance drive pad of accessory gearbox. Remove adapter plate. Change 1





Using lubricating oil, lubricate preformed packing.

(5)

Install preformed packing into groove on aft maintenance drive pad cover.

(6)

Install aft maintenance drive pad cover onto accessory gearbox. Secure using washers and nuts. Tighten nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque.

h.

Prepare engine for operation per GEK 105054, Chapter 7. Comply with any applicable instructions in packager’s manual.

i.

Motor engine per GEK 105054, Chapter 7, and leak check VSV system.

Change 1

59/(60 Blank)




WORK PACKAGE

TECHNICAL PROCEDURES LUBE OIL SAMPLING (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Lube Oil Sampling...............................................................................................................

3


GEK 105054 Volume II WP 407 00 1.


Introduction. This work package contains instructions for lube oil sampling and test analysis.

2.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Gas Turbine Assembly Replacement Gas Generator Assembly Replacement Lube and Scavenge Pump Screen, Electronic Chip Detector and Magnetic Detector Plug Inspection Oil Analysis, Particle Count Oil Analysis, Viscosity Oil Analysis, Acid Oil Analysis, Color

GEK 105054 WP 002 00 WP 300 00 WP 301 00

3.


4.


5.

WP 400 00 ARP598 ASTM D445-65 ASTM D664-58 ASTM D1500

Nomenclature


Lubricating Oil






Lube Oil Sampling. a.


b.

Obtain lube oil sample as follows: WARNING

•


•

LIQUID IS HOT AND CAN CAUSE SEVERE BURNS. SKIN AND EYE PROTECTION IS REQUIRED TO PREVENT INJURY FROM SPLASH BURNS. CAUTION

DO NOT TAKE OIL SAMPLE FROM LOW DRAIN POINT. LOW DRAIN POINT CAN CONTAIN HEAVY SEDIMENTS AND PROVIDE INCORRECT INDICATIONS. (1)

Shut down engine or take sample while operational per packager’s manual.

(2)

Obtain oil sample as follows: (a) Obtain oil sample within 30 minutes after engine shutdown. (b) Take oil sample per packager’s manual. Ensure oil extraction equipment and container are clean and free of contaminates. (c) If oil sample is obtained from a low drain point, such as scavenge oil discharge line, flow approximately 1 pint (0.5 liter) into waste container and then, without interrupting flow, obtain oil sample. NOTE

All oil samples shall be taken from the same location. c.

Label oil sample with following information: (1)

Sample Location ______________________________________ (Specific area of engine sample was obtained from)

(2)

Engine S/N __________________________________________

(3)

Oil Type _____________________________________________

(4)

Date _________________________________________________

(5)

Total Operating Hours ________________________________ 3




d.

Deliver oil sample to laboratory for analysis. Test oil sample per table 1 or table 2.

e.

If limits of table 1 or table 2 are exceeded, perform following corrective action:

f.

(1)

Inspect lube and scavenge pump chip detectors and screens per WP 400 00.

(2)

Flush and filter oil per packager’s manual.

If SOAP analysis (table 2) indicates an increasing trend in wear, monitor oil contamination through increased sampling intervals. If maximum limits are reached, perform following tasks: (1)

Replace engine per WP 300 00 or WP 301 00.

(2)

Flush oil system per step e.(2). Table 1. Lube Oil Sample Testing

Step

Test for

Procedure

Limit

1.

Total Acid Number (TAN)

Test per 2.0 ASTM D664-58

1.0

2.

Viscosity (Kinematic)

Test per ASTM D445-65

Maximum change at 100ºF (38ºC) from new oil reading -10% to +25%

3.

Color

Test per ASTM D1500

4

4.

Particle Count

Test per SAE ARP598 Range (Microns) 15-25 25-50 50-100 >100

Count (per 100 ml sample)

Visual

1,000 PPM per 10 ml sample

5.

Water

10,000 1500 200 20



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. SOAP Analysis Element 1.

2.

Normal Range

Monitor Range (On-Watch)

Shutdown Level

Iron (Fe)

0-3

4-7

8+

Silver (Ag)

0-1

2-4

5+

Aluminum (Al)

0-1

2-4

5+

Chromium (Cr)

0-4

5-7

8+

Copper (Cu)

0-5

6-10

11+

Magnesium (Mg)

0-1

2-4

5+

Nickel (Ni)

0-3

4-6

7+

Silicon (Si)

0-20

21-36

37+

Titanium (Ti)

0-3

4-6

7+

Molybdenum (Mo)

0-3

4-6

7+

Lead (Pb)

0-3

4-6

7+

Tin (Sn)

0-15

10-22

23+

Zinc (Zn)

0-10

11-17

18+

Iron (Fe)

0-8

9-13

14+

Silver (Ag)

0-3

4-6

7+

Aluminum (Al)

0-3

4-6

7+

Chromium (Cr)

0-6

7-9

10+

Copper (Cu)

0-12

13-19

20+

Magnesium (Mg)

0-6

7-9

10+

Nickel (Ni)

0-5

6-8

9+

Silicon (Si)

0-25

26-64

65+

Titanium (Ti)

0-5

6-8

9+

Molybdenum (Mo)

0-5

6-8

9+

Lead (Pb)

0-2

3-4

5+

Tin (Sn)

0-20

21-39

40+

Zinc (Zn)

0-15

16-22

23+

Atomic Absorption Method

Atomic Emission Method




WORK PACKAGE

TECHNICAL PROCEDURES HYDRAULIC PUMP FILTER ELEMENT INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Hydraulic Pump Filter Element Inspection. .....................................................................

3


GEK 105054 Volume II WP 408 00 1.


Introduction. This work package contains instructions for inspection of the hydraulic pump filter element.

2.


Number

Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Hydraulic Filter Housing and Element Replacement Illustrated Parts Breakdown


3.


4.


5.


IPB Figure No./Item

Hydraulic Filter Element Gasket

55-46 55-45




Hydraulic Pump Filter Element Inspection. a.


b.

Remove hydraulic pump filter element from housing per WP 122 00.

c.

Inspect filter bowl for large particles.

d.

Inspect filter element for contaminants.

e.

If contaminants are found, perform following steps: (1)

If found during periodic inspection, replace filter.

(2)

If found due to variable stator vane (VSV) low pressure alarm, check hydraulic pump for failure.

f.

Install hydraulic pump filter element into housing per WP 122 00.

g.

Motor engine per GEK 105054, Chapter 7, and check for leaks.




WORK PACKAGE

TECHNICAL PROCEDURES IGNITION SYSTEM FUNCTIONAL CHECK (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Ignition System Functional Check. ....................................................................................

3


GEK 105054 Volume II WP 409 00 1.


Introduction. This work package contains instructions for a functional check of the ignition system.

2.

Reference Material. Operation and Maintenance Manual, Volume I Installation/Initial Startup and Engine Operation Troubleshooting Operation and Maintenance Manual, Volume II General Maintenance Practices Ignition Exciter Replacement

3.


4.


5.


GEK 105054 Chapter 7 Chapter 10 GEK 105054 WP 002 00 WP 104 00




Ignition System Functional Check. a.

Prior to inspecting ignition system, perform following: (1)


(2)

Shut off electrical power to ignition system. Tag ignition system electrical power out of service.

(3)

Clear combustor of any residual fuel as follows: (a) Motor engine per GEK 105054, Chapter 7, for 1 minute. (b) Allow engine to coast down and stop rotation. WARNING

IGNITION SYSTEM SHALL BE INOPERATIVE FOR AT LEAST 2 MINUTES BEFORE DISCONNECTING IGNITION LEADS. IGNITION SYSTEM COULD BE CHARGED WITH LETHAL HIGH VOLTAGE. b.

If two igniter plugs are installed, check igniter operation as follows: (1)

Check 4:00 o’clock position igniter plug operation as follows: (a) Disconnect, at ignition exciter, electrical lead of igniter plug not being checked per WP 104 00. (b) Temporarily secure electrical lead of igniter plug not being checked away from ignition exciter. (c) Reapply power to ignition system per packager’s manual. Igniter plug shall energize. (d) Listen for audible cracking when igniter plug fires. (e) Remove power from ignition system per packager’s manual. (f) Reconnect, at ignition exciter, electrical lead of igniter plug not being checked per WP 104 00.

(2) c.

Repeat steps (a) through (f) for igniter plug at 5:00 o’clock position.

If single igniter plug is installed, perform steps b.(1)(c) through (e).




d.

If cracking noise is not heard when testing igniter plug(s), check out system to isolate problem. Take appropriate corrective action per GEK 105054, Chapter 10.

e.

Remove tag and restore electrical power to ignition system per packager’s manual.




WORK PACKAGE

TECHNICAL PROCEDURES VIBRATION MONITORING SYSTEM FUNCTIONAL CHECK (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Vibration Monitoring System Functional Check...............................................................

3


GEK 105054 Volume II WP 410 00 1.


Introduction. This work package contains instructions for a functional check of the vibration monitoring system installed on LM2500+ Models GK and GV gas generators and Model PK gas turbine. For LM2500+ Model PV gas turbine, consult GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title

For LM2500+ Models GK, GV gas generators and Model PK gas turbine: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Accelerometer Replacement WP 111 00 For LM2500+ Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


Part No.

Multimeter

Local Purchase

4.


5.





Vibration Monitoring System Functional Check. a.

Comply with all instructions contained in WP 002 00. NOTE

b.

c.

•

Gas generators have accelerometer located on compressor rear frame (CRF) forward flange.

•

Gas turbines with six stage power turbine have accelerometers mounted on CRF forward flange and turbine rear frame (TRF) forward flange.

•

For gas turbines with two stage high speed power turbine, consult GEK 105052 for power turbine accelerometer placement.

Perform mechanical inspection of accelerometer as follows: (1)

Inspect accelerometer(s) for physical damage. Replace as required.

(2)

Inspect accelerometer(s) mounting hardware for proper installation. If loose, reinstall per WP 111 00.

(3)

Inspect accelerometer(s) electrical leads for proper installation. If loose, reinstall mounting hardware per WP 111 00.

(4)

Inspect security of accelerometer electrical connectors to packager leads per packager’s manual.

Check accelerometer(s) for continuity and isolation as follows: NOTE Electrical problems are evident by erratic or no output from transducer, and are indicative of contaminated connector contacts, loose connector, or damaged leads at connector backshell. (1)

Using multimeter, check continuity between connector pins. Resistance shall be 1,000 megohm, minimum.

(2)

Using multimeter, check isolation between accelerometer case and each connector pin. Resistance shall be 100 megohm, minimum.




WORK PACKAGE

TECHNICAL PROCEDURES OVERSPEED INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Gas Generator Overspeed Inspection................................................................................. Power Turbine Overspeed Inspection. ...............................................................................

3 4


GEK 105054 Volume II WP 411 00 1.


Introduction. This work package provides instructions for LM2500+ Models GK, GV gas generators and Model PK gas turbine overspeed inspections. For LM2500+ Model PV gas turbine overspeed inspection, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown, for further instructions.

2.


Title

For LM2500+ Models GK, GV gas generators and Model PK gas turbine: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Procedures WP 002 00 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Power Turbine Assembly Replacement WP 302 00 Gas Generator/Gas Turbine Shipping WP 502 00 Power Turbine Shipping WP 503 00 For LM2500+ Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


4.


5.





Gas Generator Overspeed Inspection. CAUTION DO NOT ATTEMPT TO MOTOR OR OPERATE ENGINE IF OVERSPEED CONDITION HAS OCCURRED, UNTIL THOROUGH INVESTIGATION OF CONDITION HAS BEEN COMPLETED. NOTE Gas generator overspeed condition exists when high pressure compressor (HPC) rotor speed exceeds 10,370 revolutions per minute (RPM). a.


b.

Following shutdown of engine, due to gas generator overspeed condition, proceed as follows:

c.

(1)

Check gas generator instrumentation for correct operation.

(2)

Consult packager’s manual to check packager supplied control hardware and software for correct operation.

If no problems are found with instrumentation, proceed as follows: (1)

Consult packager’s manual to determine HPC rotor maximum recorded speed during overspeed condition.

(2)

Remove gas generator per WP 301 00 or gas turbine per WP 300 00.

(3)

Ship gas generator to depot for inspection per WP 502 00.


GEK 105054 Volume II WP 411 00 7.


Power Turbine Overspeed Inspection. CAUTION DO NOT ATTEMPT TO MOTOR OR OPERATE ENGINE IF OVERSPEED CONDITION HAS OCCURRED, UNTIL THOROUGH INVESTIGATION OF CONDITION HAS BEEN COMPLETED. NOTE Power turbine overspeed condition exists when power turbine rotor speed exceeds 4,978 RPM. a.

Following emergency shutdown of engine, due to power turbine overspeed condition, proceed as follows: (1)

For six stage power turbines, proceed as follows: (a) Check power turbine instrumentation for correct operation. (b) Consult packager’s manual to check packager supplied control hardware and software for correct operation.

(2) b.

For two stage power turbines, consult GEK 105052.

If no problems are found with instrumentation, proceed as follows: (1)

Consult packager’s manual to determine power turbine rotor maximum recorded speed during overspeed condition.

(2)

If power turbine rotor speed of greater than 4,978 RPM is confirmed, proceed as follows: (a) Remove power turbine per WP 302 00. (b) Ship power turbine to depot for inspection per WP 503 00.




WORK PACKAGE

TECHNICAL PROCEDURES OVERTEMPERATURE INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 4 .................... 0 Alphabetical Index Page

Subject Overtemperature Inspection. .............................................................................................

3


GEK 105054 Volume II WP 412 00 1.


Introduction. This work package contains instructions for inspection of LM2500+ Models GK and GV gas generators and Model PK gas turbine when an overtemperature condition has occurred. Overtemperature condition occurs when engine operating temperature exceeds limits established in GEK 105054, Chapter 7. Inspect LM2500+ Model PV gas turbine per GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title

For LM2500+ Models GK, GV gas generators and Model PK gas turbine: Operation and Maintenance Manual, Volume I GEK 105054 Installation/Initial Startup and Engine Operation Chapter 7 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Gas Generator/Gas Turbine Shipping WP 502 00 For LM2500+ Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


4.


5.





Overtemperature Inspection. NOTE

•

Transients into Area A do not require an overtemperature inspection, but cause of transient should be found and corrected.

•

Transients into Area B require an overtemperature inspection. If more than one transient into Area B occurs, record the first transient in engine records and find and correct cause of transient.

•

Any transient into Area C requires an overtemperature inspection. CAUTION

IF A QUESTIONABLE CONDITION EXISTS, DO NOT ATTEMPT TO MOTOR OR OPERATE THE ENGINE UNTIL A THOROUGH INVESTIGATION OF THE CONDITION HAS BEEN MADE. DO NOT REPEAT HOT STARTS, COMPRESSOR STALLS, LOAD-SHEDDING, OR OTHER PROBLEMS THAT INITIATE EMERGENCY SHUTDOWNS OR ABORTED OPERATIONS WITHOUT THOROUGH INVESTIGATION. FAILURE TO DO SO CAN RESULT IN UNDUE STRESS ON ENGINE COMPONENTS THAT MAY RESULT IN DAMAGE AND ULTIMATE FAILURE. a.


b.

Following shutdown of engine due to overtemperature condition (figure 1), proceed as follows: (1)

Check engine instrumentation for correct operation.

(2)

Check all engine and packager supplied cabling.

(3)

Consult packager’s manual to check packager supplied control hardware and software for correct operation.

c.

If two stage power turbine is installed, consult GEK 105052, Operations and Maintenance Manual, for disposition of power turbine.

d.

If no problems are found in engine instrumentation, cabling, or control system, remove gas turbine per WP 300 00, or gas generator per WP 301 00.

e.

Install gas generator or gas turbine into shipping container per WP 502 00.

f.

Ship gas generator or gas turbine to depot for further inspection.




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



WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR MISCELLANEOUS SUMP COMPONENTS INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Page

Engine Bearings Inspection................................................................................................ Insulation Blankets Inspection. ......................................................................................... Lube Oil Nozzles Inspection ............................................................................................... Miscellaneous Sump Components Inspection.................................................................... Rotating Air and Oil Seals Inspection................................................................................ Spanner Nuts Inspection. ................................................................................................... Stationary Air and Oil Seals Inspection. ...........................................................................

15 10 11 13 8 8 3


GEK 105054 Volume II WP 413 00 1.


Introduction. This work package contains instructions for LM2500+ Models GK and GV gas generator, and Model PV gas turbine, inspection of A-, B-, and C-sump components.

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Turbine Mid Frame Replacement High Pressure Turbine Rotor Replacement Compressor Front Frame Replacement Gas Generator Assembly Replacement High Pressure Compressor Rotor Inspection High Pressure Turbine Inspection

GEK 105054 WP 002 00 WP 200 00 WP 201 00 WP 210 00 WP 301 00 WP 424 00 WP 426 00


Part No.


Local Purchase




Fed Spec TT-I-735 MIL-L-23699 or MIL-L-7808





Stationary Air and Oil Seals Inspection. a.


b.

Expose A-sump by removing compressor front frame (CFF) per WP 210 00.

c

Expose B-sump as follows:

d.

e.

(1)

Separate gas generator and power turbine per WP 301 00, or packager’s manual, as applicable.

(2)


(3)

Remove high pressure turbine (HPT) rotor per WP 201 00.

Expose C-sump as follows: (1)


(2)


Inspect stationary air and oil seals per table 1 and figure 1.




•

Replacement of A-sump stationary air and oil seals shall be accomplished at depot level. Field level maintenance is limited to CFF assembly removal and reinstallation. No. 3R bearing and inner race are matched assemblies and share same serial number. Replacement of CFF shall include replacement of No. 3R bearing inner race.

•

B-sump field level component replacement is limited to the aft stationary air seal. Repair of any other B-sump component requires gas generator replacement.

•

Replacement of C-sump stationary air and oil seals shall be accomplished at depot level. Field level maintenance is limited to TMF replacement. No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of TMF shall include replacement of No. 5R bearing inner race. Table 1. Stationary Air And Oil Seals

Inspect



l. All Areas for: a. Cracks Not serviceable Not repairable 2. Seal Surfaces (Metallic Honeycomb Seal Material) for: a. Rubs or See figure l for wear Not repairable grooves groove depth limits 3. Seal Surfaces (Abradable Seal Material) for: a Rubs, grooves, Depth of damage Not repairable or missing not to exceed 50 pieces percent of rub material thickness 4. Mating (Sealing) Surfaces for: a. Pickup and Not serviceable Any amount high metal b. Nicks, dents, Any number, any Not repairable and scratches length, 0.063 in. (1.60 mm) deep, after removal of high metal, if damage does not extend completely across sealing surface

On-Site Corrective Action See NOTE See NOTE

See NOTE

Remove pickup and high metal Replace part



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Stationary Air And Oil Seals - (Cont.)

Inspect 5. Threads for: a. Damage


Not serviceable


All thread pickup and high metal shall be removed. Total removal of damage shall not exceed accumulated length of one full thread 6. HPT Cooling and Vent Stationary Air Seal for: a. Flange 0.020 in. (0.50 mm) Any amount distortion at as measured with jackscrew 6.0 in. (152 mm) parallel bar and depth micrometer b. Flange mating Not serviceable Not repairable surface c. Stripped jackNot serviceable Not repairable screw holes d. Damaged Not serviceable Not repairable bolthole


Chase threads

Straighten. Inspect for cracks. If cracked, replace seal Replace seal Replace seal Replace seal




Figure l. Engine Bearing Stationary Air and Oil Seals (Sheet 1 of 2) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. Engine Bearing Stationary Air and Oil Seals (Sheet 2 of 2) 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 413 00 7.

8.


Rotating Air and Oil Seals Inspection. a.


b.

Inspect A-sump rotating component per WP 424 00.

c.

Inspect B- and C-sump rotating components per WP 426 00.

Spanner Nuts Inspection. a.


b.

Expose A-sump by removing CFF per WP 210 00.

c.

Expose C-sump as follows:

d.

(1)


(2)


Inspect No. 3R and No. 5R bearing spanner nuts per table 2 and figure 2. Table 2. No. 3 and No. 5 Bearing Spanner Nuts

Inspect




1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace nut


Missing silver plating on all areas, except threads (No. 5 bearing only)

Any amount, if no corrosion is evident

Remove corrosion. Apply lubricating oil as protective coating

c.

Nicks, dents, or scratches


Not repairable

Replace nut



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. No. 3 and No. 5 Bearing Spanner Nuts - (Cont.)

Inspect




2. Threads for: a.

Damage

Not serviceable

All thread pickup and high metal shall be removed. Total removal of entrance thread is permissible if remainder of threads are free of damage; cumulative length of damage in other threads shall not exceed 1/2 of one complete thread

Remove damage with fine file or honing stone. Be careful not to remove protective finish unnecessarily. If entrance thread is removed, lead-in radii shall be contoured same as original

b.

Silver plating or black oxide finish missing

50 percent missing

Not repairable

Replace spanner nut

Not serviceable

Any amount

Remove high metal

Not serviceable

25 percent of slot height can be removed by blending to radius

Blend

3. Mating (Seating) Surfaces for: a.

Pickup and high metal

4. Tab Slots for: a.

Turned metal or cracked corners




Figure 2. No. 3R and No. 5R Bearing Spanner Nuts 9.

Insulation Blankets Inspection. a.


b.


c.

(1)


(2)


Inspect C-sump insulation blankets per table 3.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. Insulation Blankets

Inspect





Discoloration

Any amount

b.

Soot or oil accumulation (externally)

Any amount

Removal of soot or oil accumulation is desirable before being reinstalled

c.

Oil soaking (internally)

Not serviceable

Not repairable

Replace blanket

d.

Charring or burning

Not serviceable

Not repairable

Replace blanket

e.

Missing or loose capstan

Not serviceable

Not repairable

Replace blanket

f.

Holes

Six per side, 0.125 in. (3.17 mm) diameter, at least 6.0 in. (152 mm) apart


Replace blanket

g.

Rips or cracks

12 per side, 0.125 in. (3. 17 mm) long, at least 6.0 in. (152 mm) apart

Any number, 1.0 in. (25 mm) long, at least 6.0 in. (152 mm) apart

Replace blanket

h.

Wrinkles, dents, or snags

Any number, that does not penetrate foil skin

Any amount can be re-formed

Re-form blanket

10. Lube Oil Nozzles Inspection a.


b.


c.


d.

(1)


(2)


Inspect lube oil nozzle per table 4.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Lube Oil Nozzle On-Site Maximum Serviceable Limits

Inspect




Cracks

Not serviceable

Not repairable

Replace part

b.

Nicks, dents, and scratches (except orifices)

Any number, 0.031 in. (0.78 mm) deep, if it does not affect oil flow direction, quantity, or pattern, and does not exceed 20 percent of lube jet housing dimension adjacent to damaged area

Not repairable

Replace nozzle*

c.

Sharp (creased) bends

Not serviceable

Not repairable

Replace nozzle*

Not serviceable

Not repairable

Replace nozzle*

2. Orifices for: a.

Damage that restricts and/or distorts flow in orifice

WARNING

•

WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG. WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.

• ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

b.

Contamination

Not serviceable

Any amount that can be completely removed

Clean, with isopropyl alcohol and clean shop air



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 4. Lube Oil Nozzle

Inspect




3. Gasket Sealing Surface for: a.

Nicks and scratches

Any number, 0.010 in. (0.25 mm) in depth, after removal of high metal, if defect does not extend completely across sealing surface where gasket is placed

Not repairable

Replace nozzle*

* May be repairable. Consult GE for disposition of replaced parts. 11. Miscellaneous Sump Components Inspection. a.


b.


c


d.

e.

(1)


(2)


(3)

Remove HPT rotor per WP 201 00.



(2)


Inspect miscellaneous sump components per table 5.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. Miscellaneous Sump Components

Inspect




RETAINING RINGS, LOCKPLATE (NO. 5 BEARING) AND SPACERS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace part

b.

Missing black oxide finish


c.

Nicks or scratches


Not repairable

Replace part

d.

Bent or broken tab

Not serviceable

Not repairable

Replace part

e.

Ring bent out of alignment

Not serviceable

Not repairable

Replace part

Not serviceable

Not repairable

Replace part. If damage was caused from gas turbine operation, replace No. 5 bearing also

Not repairable

Replace part

Remove all corrosion and apply protective coating

2. Lockplate Lugs for: a.

Distortion

HEAT AND OIL SHIELDS 1. All Areas for: a.

Cracks in body

Not serviceable

b.

Nicks and scratches

Any number, any length, if they do not penetrate completely through parent metal. Remove high metal. Surfaces in mating areas shall be smooth



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. Miscellaneous Sump Components

Inspect




1. All Areas for: - (cont.) c.

Dents

Any number, 0.031 in. (0.78 mm) deep that shall not interfere with installation

Any number, any depth, that can be re-formed to near original contour and shall assemble properly

Re-form, as nearly as possible, to original contour with hand tools. Inspect for cracks. Replace if cracked

d.

Distortion

Not serviceable

Any amount that can be re-formed to near original contour and shall assemble properly

Use hand tools to re-form as nearly as possible to original contour. Inspect for cracks. Replace if cracked

12. Engine Bearings Inspection. a.


b.


c.


d.

e.

(1)


(2)


(3)




(2)


Inspect all bearings per table 6. If defect is accessible, and can be felt with recommended scriber, determine defect dimensions with pocket-sized optical comparator.




•

NO. 3R AND NO. 5R BEARINGS ARE MATCHED ASSEMBLIES. MIXING COMPONENTS FROM MATCHED BEARING ASSEMBLIES CAN RESULT IN ENGINE FAILURE. NOTE

•

Matched bearing assembly comprises inner race, cage, balls/rollers, and outer race.

•

Replacement of No. 3R bearing shall be accomplished at depot level. Field level maintenance is limited to CFF assembly removal and reinstallation and No. 3R. bearing inner race replacement. No. 3R bearing and inner race are matched assemblies and share same serial number. Replacement of CFF shall include replacement of No. 3R bearing inner race.

•

No. 4B and 4R bearings are not field replaceable. If bearings are found beyond on-site serviceable limits, replace gas generator.

•

Replacement of No. 5R bearing shall be accomplished at depot level. Field level maintenance is limited to TMF and No. 5R bearing inner race replacement. No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of TMF shall include replacement of No. 5R bearing inner race. Table 6. Engine Bearings

Inspect




l. Ball and Rollers for: a.

Fatigue pitting, spalling (as evidenced by relatively deep cavities with fractured appearance on sides), and cracks

Not serviceable

Not repairable

See CAUTION and NOTE



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Engine Bearings - (Cont.)

Inspect




l. Ball and Rollers for: - (cont.) b.

Corrosion pitting (as evidenced by relatively shallow irregularly shaped ragged cavities with either reddish or dark color)

Any number, that cannot be felt with 0.030 in. (0.76 mm) radius scriber

Not repairable


c.

Rollers for axial scratches or scores

Not serviceable, if detected with 0.030 in. (0.76 mm) radius scriber

Not repairable


d.

Balls or rollers for crossed scratches

Not serviceable, if detected with 0.030 in. (0.76 mm) radius scriber when passed lightly across junction(s) of scratches

Not repairable


e.

Circumferential scratches or scores

Acceptable, if not detected with 0.030 in. (0.76 mm) radius scriber

Not repairable


f.

Nicks and dents

Acceptable, if not felt with 0.030 in. (0.76 mm) radius scriber

Not repairable





Inspect




l. Ball and Rollers for: - (cont.) g.

Skidding wear, as can be visually apparent by burnished over-all appearance or flat spots

Not serviceable

Not repairable


h.

Heat discoloration

Accept bright polished steel to straw color only

Not repairable


i.

True brinnelling

Not serviceable

Not repairable


j.

Stains

Any amount

k.

Fit in cage pocket

No tightness allowed. Elements shall be retained

Not repairable


l.

End wear on rollers of No. 3 bearing


Not repairable





Inspect




2. Inner and/or Outer Races for: a.


Not serviceable

Not repairable


b.

Corrosion and pitting (as evidenced by relatively shallow irregular shaped ragged cavities with either reddish or dark color)

Not serviceable

Not repairable


(1)

Active surfaces on separable races


Not repairable


(2)

Nonactive surfaces

Acceptable, if pits cannot be detected by 0.045 in. (1.14 mm) radius scriber after localized hand polishing with crocus cloth. After polishing, surface finish shall be as smooth as original

Not repairable





Inspect




2. Inner and/or Outer for Races: - (cont.) NOTE No polishing is permitted on active surfaces. c.

d.

Scratches and scores (1)

Active surfaces

Acceptable, if cannot be felt with 0.030 in. (0.76 mm) radius scriber, after removal of high metal

Not repairable


(2)

Nonactive surfaces

Acceptable, if cannot be felt with 0.045 in. (1.14 mm) radius scriber, after removal of high metal

Not repairable


Nicks, dents, or indentations


Not repairable


(1)

For bearings with rolling elements less than 0.500 in. (12.70 mm) diameter, 0.030 in. (0.76 mm) in greatest dimension. With rolling elements greater than 0.500 in. (12.70 mm) diameter, 0.040 in. (1.01 mm) in greatest dimension

Not repairable


Active surfaces




Inspect




2. Inner and/or Outer for Races: - (cont.) (2) Nonactive surfaces

0.090 in. (2.28 mm) in greatest dimension, 0.030 in. (0.76 mm) in axial direction, if damage extends into active surface of race. Remove high metal on clamping surfaces

Not repairable


Not repairable


e.

True brinelling

Not serviceable

f.

Stains

Any amount

g.

Skidding wear, as can be visually apparent by burnished overall appearance, or localized smearing or wiping of material

Not serviceable

Not repairable


3. Cages for: a.

Chips, cracks, distortion, or heat discoloration of plated surfaces

Not serviceable

Not repairable


b.

Missing or worn rolling element retainers

Not serviceable

Not repairable


c.

Smooth indentations

Accept defects 0.200 in. (5.08 mm) in greatest dimension, if they do not extend into or deform functional surfaces

Not repairable





Inspect




3. Cages for: - (cont.) d.

Wear through of plating in ball or roller pockets down to cage parent metal

Not serviceable

Not repairable


e.

Stains

Any amount

f.

Heat discoloration

Straw color acceptable

Not repairable


g.

Silver plating

Missing plating on nonfunctional cage surfaces is acceptable

Not repairable






TECHNICAL PROCEDURES GAS TURBINE MISCELLANEOUS SUMP COMPONENTS INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.


Page

Engine Bearings Inspection................................................................................................ Insulation Blankets Inspection. ......................................................................................... Lube Oil Nozzles Inspection. .............................................................................................. Miscellaneous Sump Components Inspection.................................................................... Rotating Air and Oil Seals Inspection................................................................................ Spanner Nuts Inspection. ................................................................................................... Stationary Air and Oil Seals Inspection. ...........................................................................

20 14 16 17 9 11 3




Introduction. This work package contains instructions for inspection of A-, B-, C-, and D-sump components.

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Turbine Mid Frame Replacement High Pressure Turbine Rotor Replacement Compressor Front Frame Replacement Gas Generator and Power Turbine Separation and Joining Gas Generator Assembly Replacement High Pressure Compressor Rotor Inspection High Pressure Turbine Inspection

GEK 105054 WP 002 00 WP 200 00 WP 201 00 WP 210 00 WP 216 00 WP 301 00 WP 424 00 WP 426 00


Part No.


Local Purchase

Consumable Material Nomenclature



Fed Spec TT-I-735 MIL-L-23699 or MIL-T-5544





Stationary Air and Oil Seals Inspection. a.


b.

Expose A-sump by removing compressor front frame (CFF) per WP 210 00.

c.


d.

(1)


(2)


(3)

Remove high pressure turbine (HPT) rotor per WP 201 00.



(2)


e.

D-sump components are not accessible at field level. Contact GE M&I for disposition of Dsump components.

f.

Inspect stationary air and oil seals per table 1 and figure 1.




•

Replacement of A-sump stationary air and oil seals shall be accomplished at depot level. Field level maintenance is limited to CFF assembly removal and reinstallation. No. 3R bearing and inner race are matched assemblies and share same serial number. Replacement of CFF shall include replacement of No. 3R bearing inner race.

•

B-sump field level component replacement is limited to the aft stationary air seal. Repair of any other B-sump component requires gas generator replacement.

•

Replacement of C-sump stationary air and oil seals shall be accomplished at depot level. Field level maintenance is limited to TMF replacement. No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of TMF shall include replacement of No. 5R bearing inner race. Table 1. Stationary Air And Oil Seals

Inspect




l. All Areas for: a.

Cracks

Not serviceable

Not repairable

See NOTE

2. Seal Surfaces (Metallic Honeycomb Seal Material) for: a.

Rubs or grooves

See figure l for wear groove depth limits

Not repairable

See NOTE

Not repairable

See NOTE

3. Seal Surfaces (Abradable Seal Material) for: a.

Rubs, grooves, or missing pieces

Depth of damage not to exceed 50 percent of rub material thickness

4. Mating (Sealing) Surfaces for: a.


Not serviceable

Any amount

Remove pickup and high metal

b.


Any number, any length, 0.063 in. (1.60 mm) deep, after removal of high metal, if damage does not extend completely across sealing surface

Not repairable

See NOTE



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Stationary Air And Oil Seals - (Cont.)

Inspect




5. Threads for: a.

Damage

Not serviceable

All thread pickup and high metal shall be removed. Total removal of damage shall not exceed accumulated length of one full thread

Chase threads

6. HPT Cooling and Vent Stationary Air Seal for: a.

Flange distortion at jackscrew

0.020 in. (0.50 mm) as measured with 6.0 in. (152 mm) parallel bar and depth micrometer

Any amount

Straighten. Inspect for cracks. If cracked, replace seal

b.

Flange mating surface

Not serviceable

Not repairable

See NOTE

c.

Stripped jackscrew holes

Not serviceable

Not repairable

See NOTE

d.

Damaged bolthole

Not serviceable

Not repairable

See NOTE




Figure l. Engine Bearing Stationary Air and Oil Seals (Sheet 1 of 3) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.









Rotating Air and Oil Seals Inspection. a.


b.

Inspect A-sump rotating component per WP 424 00.

c.

Inspect B-sump rotating components per WP 426 00.

d.

Expose C-sump components as follows: (1)


(2)


e.


f.

Inspect engine bearing rotating air and oil seals per table 2 and figure 2. Table 2. No. 6R Bearing Rotating Air And Oil Seals

Inspect





Cracks-except seal serration outside diameter (OD)

Not serviceable

Not repairable

Replace part



Not serviceable

Any amount


b.

Nicks, dents, scores, and scratches on end faces

Any number, any length, 0.063 in. (1.60 mm) deep, after removal of high metal, if damage does not extend completely across seating surface

Not repairable

Replace part



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. No. 6R Bearing Rotating Air And Oil Seals - (Cont.)

Inspect




2. Mating (Seating) Surfaces for: - (cont.) c.

Nicks or dents on OD

Three per 6.0 in. (152 mm) of each serration circumference, 0.047 in. (1.19 mm) deep and 0.125 in. (3.17 mm) long, after removal of high metal

Not repairable

Replace part

3. Seal Serrations for: a.

Wear at OD

Within serviceable limits of figure 2

Not repairable

Replace part

b.

Turned metal on serration OD

Any amount, if OD wear limit is not exceeded, after removal of high metal

Not repairable

Replace part

c.

Nicks or dents on face


Not repairable

Replace part

d.

Cracks originating from OD

Not serviceable

Three cracks per 6.0 in. (152 mm) of each serration circumference can be blended out to depth of 0.047 in. (1.19 mm) and 0.125 in. (3.17 mm) long

Blend. Inspect after blending

e.

Aluminum oxide coating missing (where applicable)

40 percent can be missing on outer portion that mates to stationary seal

Not repairable

Replace part



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. No. 6R Bearing Rotating Air And Oil Seals - (Cont.)

Inspect




4. Seal Bore for: a.

8.

Axial score marks

Any number, any length, 0.010 in. (0.25 mm) deep and 0.031 in. (0.78 mm) wide, after removal of high metal, if no more than five percent of area is affected in any 90 degree sector

Not repairable

Replace part

Spanner Nuts Inspection. a.


b.


c.



(2)


d.


e.

Inspect No. 3R, No. 5R, and No. 6R bearing spanner nuts per table 3 and figure 3.




Figure 2. No. 6R Bearing Rotating Air and Oil Seals 12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. No. 3, No. 5, and No. 6 Bearing Spanner Nuts

Inspect





Cracks

Not serviceable

Not repairable

Replace nut


Missing silver plating on all areas, except threads (No. 5 bearing only)


Remove corrosion. Apply lubricating oil as protective coating

c.



Not repairable

Replace nut

2. Threads for: a.

Damage

Not serviceable

All thread pickup and high metal shall be removed. Total removal of entrance thread is permissible if remainder of threads are free of damage; cumulative length of damage in other threads shall not exceed 1/2 of one complete thread

Remove damage with fine file or honing stone. Be careful not to remove protective finish unnecessarily. If entrance thread is removed, lead-in radii shall be contoured same as original

b.

Silver plating or black oxide finish missing

50 percent missing

Not repairable

Replace spanner nut

Any amount

Remove high metal



Not serviceable



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 3. No. 3, No. 5, and No. 6 Bearing Spanner Nuts - (Cont.) On-Site Maximum Serviceable Limits

Inspect



4. Tab Slots for: a.

9.

Turned metal or cracked corners

Not serviceable

25 percent of slot height can be removed by blending to radius

Blend

Insulation Blankets Inspection. a.


b.



(2)


Figure 3. No. 3R, No. 5R, and No. 6R Bearing Spanner Nuts 14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.




d.

Inspect C-sump insulation blankets per table 4. Table 4. Insulation Blankets

Inspect





Discoloration

Any amount

b.

Soot or oil accumulation (externally)

Any amount

Removal of soot or oil accumulation is desirable before being reinstalled

c.

Oil soaking (internally)

Not serviceable

Not repairable

Replace blanket

d.

Charring or burning

Not serviceable

Not repairable

Replace blanket

e.

Missing or loose capstan

Not serviceable

Not repairable

Replace blanket

f.

Holes



Replace blanket

g.

Rips or cracks

12 per side, 0.125 in. (3. 17 mm) long, at least 6.0 in. (152 mm) apart

Any number, 1.00 in. (25.4 mm) long, at least 6.0 in. (152 mm) apart

Replace blanket

h.

Wrinkles, dents, or snags

Any number, that does not penetrate foil skin

Any amount can be re-formed

Re-form blanket




10. Lube Oil Nozzles Inspection. a.


b.


c.



(2)


d.


e.

Inspect lube oil nozzle per table 5. Table 5. Lube Oil Nozzle

Inspect





Cracks

Not serviceable

Not repairable

Replace part

b.

Nicks, dents, and scratches (except orifices)

Any number, 0.031 in. (0.78 mm) deep, if it does not affect oil flow direction, quantity, or pattern, and does not exceed 20 percent of lube jet housing dimension adjacent to damaged area

Not repairable

Replace nozzle*

c.

Sharp (creased) bends

Not serviceable

Not repairable

Replace nozzle*

Not serviceable

Not repairable

Replace nozzle*

2. Orifices for: a.

Damage that restricts and/or distorts flow in orifice



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 5. Lube Oil Nozzle On-Site Maximum Serviceable Limits

Inspect



2. Orifices for: - (cont.) WARNING

b.

•

WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG. WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.

•

ALCOHOL IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

Contamination

Not serviceable

Any amount that can be completely removed

Clean, with isopropyl alcohol and clean shop air

Not repairable

Replace nozzle*

3. Gasket Sealing Surface for: a.

Nicks and scratches

Any number, 0.010 in. (0.25 mm) in depth, after removal of high metal, if defect does not extend completely across sealing surface where gasket is placed

* May be repairable. Consult GE for disposition of replaced parts. 11. Miscellaneous Sump Components Inspection. a.


b.


c.

Expose B-sump as follows: (1)


(2)


(3)

Remove HPT rotor per WP 201 00. 17


GEK 105054 Volume II SWP 413 01 d.




(2)


e.


f.

Inspect miscellaneous sump components per table 6. Table 6. Miscellaneous Sump Components

Inspect




RETAINING RINGS, LOCKPLATE (NO. 5R BEARING), AND SPACERS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace part

b.

Missing black oxide finish


c.

Nicks or scratches


Not repairable

Replace part

d.

Bent or broken tab

Not serviceable

Not repairable

Replace part

e.

Ring bent out of alignment

Not serviceable

Not repairable

Replace part

Not serviceable

Not repairable

Replace part. If damage was caused from gas turbine operation, replace No. 5 bearing also

Remove all corrosion and apply protective coating

2. Lockplate Lugs for: a.

Distortion



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 6. Miscellaneous Sump Components - (Cont.)

Inspect




HEAT AND OIL SHIELDS 1. All Areas for: a.

Cracks in body

Not serviceable

Not repairable

Replace part

b.

Nicks and scratches

Any number, any length, if they do not penetrate completely through parent metal. Remove high metal. Surfaces in mating areas shall be smooth

c.

Dents

Any number, 0.031 in. (0.78 mm) deep that shall not interfere with installation

Any number, any depth, that can be re-formed to near original contour and shall assemble properly

Re-form, as nearly as possible, to original contour with hand tools. Inspect for cracks. Replace if cracked

d.

Distortion

Not serviceable

Any amount that can be re-formed to near original contour and shall assemble properly

Use hand tools to re-form as nearly as possible to original contour. Inspect for cracks. Replace if cracked




12. Engine Bearings Inspection. a.


b.


c.


d.

(1)


(2)


(3)




(2)


e.


f.

Inspect all bearings per table 7. If defect is accessible, and can be felt with recommended scriber, determine defect dimensions with pocket-sized optical comparator.




•

NO. 3R AND NO. 5R BEARINGS ARE MATCHED ASSEMBLIES. MIXING COMPONENTS FROM MATCHED BEARING ASSEMBLIES CAN RESULT IN ENGINE FAILURE. NOTE

•

Matched bearing assembly comprises inner race, cage, balls/rollers, and outer race.

•

Replacement of No. 3R bearing shall be accomplished at depot level. Field level maintenance is limited to CFF assembly removal and reinstallation and No. 3R. bearing inner race replacement. No. 3R bearing and inner race are matched assemblies and share same serial number. Replacement of CFF shall include replacement of No. 3R bearing inner race.

•

Replacement of No. 5R bearing shall be accomplished at depot level. Field level maintenance is limited to TMF and No. 5R bearing inner race replacement. No. 5R bearing and inner race are matched assemblies and share same serial number. Replacement of TMF shall include replacement of No. 5R bearing inner race.

•

No. 4B, 4R, 7B, and 7R bearings are not field replaceable. If No. 4B and 4R bearings are found beyond on-site serviceable limits, replace gas generator. If No. 7B and 7R bearings are found beyond on-site serviceable limits, replace power turbine. Table 7. Engine Bearings

Inspect




l. Ball and Rollers for: a.


Not serviceable

Not repairable





Inspect




l. Ball and Rollers for: - (cont.) b.

Corrosion pitting (as evidenced by relatively shallow irregularly shaped ragged cavities with either reddish or dark color)

Any number that cannot be felt with 0.030 in. (0.76 mm) radius scriber

Not repairable


c.

Rollers for axial scratches or scores

Not serviceable, if detected with 0.030 in. (0.76 mm) radius scriber

Not repairable


d.

Balls or rollers for crossed scratches

Not serviceable, if detected with 0.030 in. (0.76 mm) radius scriber when passed lightly across junction(s) of scratches

Not repairable


e.

Circumferential scratches or scores

Acceptable, if not detected with 0.030 in. (0.76 mm) radius scriber

Not repairable


f.

Nicks and dents


Not repairable


(1)

0.020 in. (0.50 mm) in greatest dimension

Not repairable


Elements less than 0.500 in. (12.70 mm) diameter




Inspect




l. Ball and Rollers for: - (cont.) (2)

Elements 0.500 in. (12.70 mm) diameter but less than 0.750 in. (19.05 mm) diameter


Not repairable


(3)

Elements 0.750 in. (19.05 mm) and greater


Not repairable


g.

Skidding wear, as can be visually apparent by burnished over-all appearance or flat spots

Not serviceable

Not repairable


h.

Heat discoloration

Accept bright polished steel to straw color only

Not repairable


i.

True brinnell

Not serviceable

Not repairable


j.

Stains

Any amount

k.

Fit in cage pocket

No tightness allowed. Elements shall be retained

Not repairable


l.

End wear on rollers of No. 3 bearing


Not repairable





Inspect




2. Inner and/or Outer Races for: a.


Not serviceable

Not repairable


b.

Corrosion and pitting (as evidenced by relatively shallow irregular shaped ragged cavities with either reddish or dark color)

Not serviceable

Not repairable


(1)

Active surfaces on separable races


Not repairable


(2)

Nonactive surfaces

Acceptable, if pits cannot be detected by 0.045 in. (1.14 mm) radius scriber after localized hand polishing with crocus cloth. After polishing, surface finish shall be as smooth as original

Not repairable





Inspect




NOTE No polishing is permitted on active surfaces. 2. Inner and/or Outer Races for: - (cont.) c.

d.

Scratches and scores (1)

Active surfaces

Acceptable, if cannot be felt with 0.030 in. (0.76 mm) radius scriber after removal of high metal

Not repairable


(2)

Nonactive surfaces

Acceptable, if cannot be felt with 0.045 in. (1.14 mm) radius scriber after removal of high metal

Not repairable


Nicks, dents, or indentations


Not repairable


(1)

For bearings with rolling elements less than 0.500 in. (12.70 mm) diameter, 0.030 in. (0.76 mm) in greatest dimension. With rolling elements greater than 0.500 in. (12.70 mm) diameter, 0.040 in. (1.01 mm) in greatest dimension

Not repairable


Active surfaces




Inspect




2. Inner and/or Outer Races for: - (cont.) (2)

Nonactive surfaces

0.090 in. (2.28 mm) in greatest dimension, 0.030 in. (0.76 mm) in axial direction, if damage extends into active surface of race. Remove high metal on clamping surfaces

Not repairable


Not repairable


e.

True brinelling

Not serviceable

f.

Stains

Any amount

g.

Skidding wear, as can be visually apparent by burnished overall appearance, or localized smearing or wiping of material

Not serviceable

Not repairable


3. Cages for: a.

Chips, cracks, distortion, or heat discoloration of plated surfaces

Not serviceable

Not repairable


b.

Missing or worn rolling element retainers

Not serviceable

Not repairable


c.

Smooth indentations

Accept defects 0.200 in. (5.08 mm) in greatest dimension, if they do not extend into or deform functional surfaces

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 7. Engine Bearings - (Cont.) Inspect




3. Cages for: - (cont.) d.

Wear through of plating in ball or roller pockets down to cage parent metal

Not serviceable

Not repairable


e.

Stains

Any amount

f.

Heat discoloration

Straw color acceptable

Not repairable


g.

Silver plating

Missing plating on nonfunctional cage surfaces is acceptable

Not repairable





WORK PACKAGE

TECHNICAL PROCEDURES VARIABLE STATOR VANE OFF-SCHEDULE INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Variable Stator Vane Off-Schedule Operation Inspection. ...............................................

3


GEK 105054 Volume II WP 414 00 1.


Introdu ction. Variable stators vanes (VSV) operated with misassembled, bent, or broken actuation arms, with broken connector links, or with actuation rings with elongated actuation arm pinholes will result in off-schedule vane condition that requires special handling of high pressure compressor (HPC) rotor blades in stage adjacent to vane stage containing discrepant actuation arm or connector link.

2.

3.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices High Pressure Compressor Rotor Blades Replacement External Engine Inspection Borescope Inspection

GEK 105054 WP 002 00 WP 215 00 WP 403 00 WP 406 00


Part No.

Protractor, Electronic Gage, Sight - VSV Actuation Arms Gage, Sight - VSV Stage 5 Actuation Arms

1C8070G06 2C6966G07 2C8016G03

4.


5.

Expendable Material. None required




Variable Stator Vane Off-Schedule Operation Inspection. a.


b.

Inspect external engine surfaces per WP 403 00.

c.

Inspect VSV actuation arms as follows: (1)

Inspect inlet guide vane (IGV) and stages 0 through 6 vanes for off-schedule condition. Inspect vanes (figure 1) for conditions listed in table 1.

(2)

Visually inspect IGV and stage 0 actuation arms for broken, distorted, or bent arms. Replace any arms found in this condition.

(3)

Using sight gage tools, determine amount of off-schedule as follows: (a) Using sight gage, 2C6966, determine angle for stages 1 through 4. (b) Using sight gage, 2C8016, determine angle for stages 5 and 6. (c) If desired, electronic protractor, 1C8070, can be used in place of sight gages when checking for off-schedule angles.

(4)

Locate gage over vane tangs and around retaining nut and sleeve. Clear Plexiglas arm extends over lever arm and has lines scribed at 0 degrees ± 2 degrees, and ± 4 degrees. Table 1. VSV Off-Schedule Conditions

Condition

Indication

Inspection

NOTE Use sight gage tools to determine amount of off-schedule. 1.

Bent, distorted, or broken actuation arms or connector links

VSV actuation components are often damaged during maintenance procedures. Figure 1 shows typical actuation arm damage

Inspect VSV actuation hardware for general conditions per paragraph 6

2.

Misassembled actuation arms to connector links (at 3:00 and 9:00 o’clock positions)

Actuation arm pins can be installed in connector link recess areas instead of correct pinholes

Check connector link actuation arms for side to side (loose) movement

3.

Actuation rings or actuation arms with elongated pinholes

Excessive wear of actuation arm pin, actuation ring, or pin is not secure (loose) to actuation arm

Check actuation arms for side to side (loose) movement




Figure 1. Variable Stator Vane Actuation Arm Inspection d.

If off-schedule condition is found, proceed as follows: (1)

Record affected stage and number of degrees of off-schedule condition.

(2)

Complete corrective action requirements per table 2. Table 2. VSV Off-Schedule Corrective Action Condition

Corrective Action

1.

Off-Schedule is 2 degrees or less

No action required

2.

Off-schedule is more than 2 degrees but less than 4 degrees

a. Replace defective VSV actuation components b. Perform borescope inspection of one stage forward and two stages aft of affected stage per WP 406 00

3.

Off-schedule is 4 degrees or more, or has broken connector link on: IGV

Perform borescope inspection of two stages aft of affected stage per WP 406 00

Stage 0

Replace two downstream stages of HPC rotor blades per WP 215 00

Stages 1 through 6 vanes

Replace one upstream and two downstream stages of HPC rotor blades per WP 215 00




WORK PACKAGE

TECHNICAL PROCEDURES FUEL SYSTEM INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Fuel System Inspection.......................................................................................................

3


GEK 105054 Volume II WP 415 00 1.


Introduction. This work package contains instructions for visual inspection of the fuel system.

2.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Fuel System Replacement

GEK 105054 WP 002 00 WP 101 00

3.


4.


5.





Fuel System Inspection. a.


b.

Inspect fuel system per table 1 and figures 1 through 4. Table 1. Fuel System Inspection Inspect


FUEL MANIFOLDS 1. Liquid Fuel Manifold for: a. Cracks and Not serviceable splits b. Dents and flat Any number on areas shrouded portion c. Nicks and Any number, 0.005 scores in. (0.13 mm) deep d. Wear at Any number, 0.005 clamping in. (0.13 mm) deep locations e. Misalignment Not serviceable 2. Natural Gas Manifold for: a. Cracks and Not serviceable splits b. Dents and flat Any number, 0.060 areas in. (1.52 mm) deep c. Nicks and Any number, 0.010 scores in. (0.25 mm) deep d. Wear at Any amount, 0.010 clamping in. (0.25 mm) deep locations 3. Dual Fuel/Liquid Manifolds for: a. Cracks and Not serviceable splits b. Dents and flat Any number, 0.020 areas in. (0.51 mm) deep c. Nicks and Any number, 0.005 scores in. (0.13 mm) deep Any amount, 0.020 d. Wear on wear sleeves in. (0.51 mm) deep


Not repairable Not repairable Not repairable Not repairable


Replace manifold per WP 101 00 Replace manifold per WP 101 00 Replace manifold per WP 101 00 Replace manifold per WP 101 00

Any amount

Realign manifold per WP 101 00

Not repairable

Replace manifold per WP 101 00 Replace manifold per WP 101 00 Blend/replace

Not repairable Any number, 0.015 in. (0.38 mm) deep Any amount, 0.015 in. (0.38 mm) deep

Not repairable Not repairable Any number, 0.010 in. (0.25 mm) deep Not repairable

Blend

Replace manifold per WP 101 00 Replace manifold per WP 101 00 Blend/Replace Replace manifold per WP 101 00



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Fuel System Inspection - (Cont.)

Inspect


3. Dual Fuel/Liquid Manifolds for: (cont.) e. Misalignment Not serviceable 4. Steam Manifold for: a. Cracks and splits b. Dents and flat areas c. Nicks and scores d. Wear at clamping locations e. Misalignment FUEL TUBES 1. Supply Tube for: a. Cracks and splits b. Wrinkles and kinks in bend ID c. Dents and flat areas d. Nicks and scores



Any amount


Not serviceable

Not repairable

Any number, 0.060 in. (1.52 mm) Any number, 0.010 in. (0.25 mm) deep Any amount 0.010 in. (0.25 mm) deep

Not repairable

Replace manifold per WP 101 00 Replace manifold per WP 101 00 Blend/Replace

Not serviceable

Any amount


Not serviceable

Not repairable

Two percent of tube OD

Not repairable

Replace tube per WP 101 00 Replace tube per WP 101 00

Any number, 0.020 in. (0.51 mm) Any number, 0.005 in. (0.127 mm) deep

Not repairable

Any number, 0.015 in. (0.38 mm) deep Any amount, 0.015 in. (0.38 mm) deep


e.

Wear at clamping locations



f.

Misalignment

Not serviceable

Any amount

Blend/Replace

Replace tube per WP 101 00 Blend to remove damage, but not beyond depth of damage. Contour shall be smooth and polished Blend to remove damage, but not beyond depth of damage. Contour shall be smooth and polished Realign tube per WP 101 00



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Fuel System Inspection - (Cont.)

Inspect




2. Fittings and Connectors for: a.

Leakage

Not serviceable


Polish sealing surface and retorque or replace tube per WP 101 00

b.

Looseness

Not serviceable

Any amount

Retorque tube per WP 101 00

Not serviceable

Not repairable

Replace fuel nozzle per WP 101 00

Not serviceable

Any amount

Remove carbon deposit and inspect for carbon cause

Not serviceable

Not repairable

Replace part

Max of 0.020 in. (0.51 mm) deep

Not repairable

Replace part

FUEL NOZZLES 1. All Fuel Nozzles for a.

Cracks

2. Fuel Nozzle Orifices a.

Carbon deposit or visible plugging

3. Face for: a.

Spalling

4. Tip for: a.

Wear




Figure 1. Liquid Fuel Nozzle

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



Figure 3. Gas Fuel Nozzle

Figure 4. Gas/Steam Fuel Nozzle 7/(8 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES COMPRESSOR FRONT FRAME INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Compressor Front Frame Inspection. ................................................................................ Compressor Front Frame Parts Repair. ............................................................................ Compressor Front Frame Parts Replacement. ..................................................................

3 3 3


GEK 105054 Volume II WP 416 00 1.


Introduction. This work package provides instructions for the inspection and repair of the compressor front frame (CFF).

2.


Number

Operation and Maintenance Manual, Volume II Compressor Front Frame Replacement Gas Generator Miscellaneous Sump Components Replacement and Inspection Gas Turbine Miscellaneous Sump Components Replacement and Inspection Illustrated Parts Breakdown

GEK 105054 WP 210 00

3.


4.


5.

WP 413 00 SWP 413 01 GEK 105055

Nomenclature


Dry Ice

Fed Spec BB-C-104

Expendable Material. Not required.



Compressor Front Frame Inspection. a.

7.

Inspect CFF per table 1 and figure 1. Refer to WP 413 00 and SWP 413 01 for sump component inspection.

Compressor Front Frame Parts Repair. a.

8.


Repair of CFF parts are limited to CFF replacement, high metal removal, chasing threads or installing inserts, tightening or replacing bolts, tightening or replacing rivets, and replacing nut or gang channel assemblies. See table 1 as applicable.

Compressor Front Frame Parts Replacement. a.

Replace CFF parts as directed during inspection operations. See table 1 as applicable.




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


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Front Frame Inspect



CASE 1. All Surfaces (unless otherwise specified) for: a. Cracks Not serviceable Not repairable b.


Any number, any length, 0.016 in. (0.40 mm) deep, after removal of high metal, if not extended across mating (sealing) surfaces 2. Instrumentation Pads for: a. Damaged Not serviceable threads

3. Forward and Aft Flanges for: a. Cracks One crack per one bolthole per flange from bolthole to outside diameter (OD) b. Deformation Not serviceable

Not repairable


Replace CFF per WP 210 00* Replace CFF per WP 210 00*

Any amount

One complete thread can be removed by chasing threads or installing insert

Not repairable

Replace CFF per WP 210 00*

Not repairable


4. Air Seal Pressurization Port and Vent Port Pads for: a. Nicks, scores, Any number, any Not repairable and scratches length, 0.010 in. (0.25 mm) deep, after removal of high metal, if not extended completely across sealing surface b. Damaged Not serviceable Any amount threads


One complete thread can be removed by chasing threads or installing insert 5



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Front Frame - (Cont.)

Inspect




5. Gas Generator Main Engine Mounts for: a.

Cracks

Not serviceable

Not repairable


b.



Any amount

Remove high metal and surface blend to original contour

Not serviceable

Not repairable


6. CFF Handling Mounts for: a.

Cracks

STRUTS 1. All Surfaces for: a.

Parent metal cracks

Not serviceable

Not repairable

Replace CFF per Wp 210 00*

b.

Weld cracks

Not serviceable

Not repairable


c.



Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Front Frame - (Cont.) Inspect




1. All Surfaces for: - (cont.) d.

Dents

Any number smooth contour dents, 0.250 in. (6.35 mm) deep. Contour rate of change not to exceed 0.10 in. per 1.00 in. (2.54 mm per 25.4 mm)

Not repairable


NO. 3 BEARING HOUSING AND NO. 3 BEARING HOUSING OIL SEAL SUPPORT 1. All Surfaces (unless otherwise specified) for: a.

Cracks

Not serviceable

Not repairable


b.


Any number, any length, 0.010 in. (0.25 mm) deep, after removal of high metal, if defect does not extend completely across sealing surface(s)

Not repairable


c.

Dents

Any number smooth contour dents, 0.063 in. (1.60 mm) deep except on sealing surface(s). Contour rate of change not to exceed 0.10 in. per 1.00 in. (2.54 mm per 25.4 mm)

Not repairable


2. Bearing Housing and Seal Support to Hub Mounting bolt for: a.

Loose or missing bolts

Not serviceable

Any amount

Tighten or replace bolts

Thread damage

Not serviceable

Not repairable

Replace bolt



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Front Frame - (Cont.)

Inspect




3. Bearing Oil Seal Support Gang Channels for: a.

Loose, missing, or high rivets

Not serviceable

Any amount

Tighten or replace rivet(s). Rivet head shall be flush or below face of flange

b.

Loss of nut, or nut selflocking quality

Not serviceable

Any amount

Replace nut or gang channel assembly*

4. Bearing Housing and Oil Seal Support Threaded Inserts for: a.

Loose or damaged inserts

Not serviceable

Any amount

Install new insert

* May be repairable. Contact GE for disposition of replaced parts.




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE RECOUP METERING SPACER SELECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Recoup Metering Spacer Selection. ...........................................................

3


GEK 105054 Volume II WP 417 00 1.


Introduction. This work package provides instructions for selecting proper size high pressure (HP) recoup metering spacer to maintain engine within preferred operating range. The metering spacer is used to adjust engine HP recoup cavity pressure.

2.


Number

Operation and Maintenance Manual, Volume I LM2500+ SAC System Descriptions Operation and Maintenance Manual, Volume II General Maintenance Practices Illustrated Parts Breakdown

GEK 105054 Chapter 5 GEK 105054 WP 002 00 GEK 105055

3.


4.


5.

Nomenclature


Thread Lubricant



IPB Figure No./Item

Metering Spacer Metering Spacer Boss Seal Boss Seal

47-52 48-52 47-47 48-47




High Pressure Recoup Metering Spacer Selection. NOTE

•

Maintenance of engine HP recoup cavity pressure within defined limits is required to ensure No. 4B bearing life. Refer to GEK 105054, Chapter 5, for monitoring requirements.

•

During initial buildup and testing of engine, HP recoup cavity pressure is adjusted to acceptable limits using the proper size metering spacers. Periodic monitoring and, if necessary, an adjustment of metering spacers is required in service to maintain HP recoup cavity pressure within limits. Seal clearance leakage flow can change in service, particularly on new or recently overhauled engines, raising HP recoup pressure at a given set of conditions.

a.


b.

Check and record part number of left and right metering spacers (4, figures 1 and 2). Determine corresponding spacer size from table 1. Left and right metering spacers should have same part number. If in doubt, remove metering spacers and establish actual orifice diameter(s).

c.

Use at least one of two available HP recoup pressure taps (5) located upstream measuring HP recoup pressure.

d.

Use average of left and right side HP recoup pressure readings if both measurements are recorded. Table 1. HP Recoup Metering Spacer Size Part No.

Orifice Diameter

L34518P03

0.298-0.302 inch

(7.57-7.67 mm)

L34518P04

0.398-0.402 inch

(10.11-10.21 mm)

L34518P05

0.498-0.502 inch

(12.65-12.75 mm)

L34518P06

0.598-0.602 inch

(15.19-15.30 mm)

L34518P07

0.698-0.702 inch

(17.73-17.83 mm)

L34518P08

0.798-0.802 inch

(20.37-20.27 mm)

L34518P09

0.898-0.902 inch

(22.81-22.91 mm)

L34518P10

0.998-1.002 inch

(25.35-25.45 mm)




Figure 1. Left HP Recoup Spacer Configuration 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. Right HP Recoup Spacer Configuration 5 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 417 00 7.


Adjustment Procedure For All GK, GV, PK, and PV Models. a.

During Engine Operation between 9000 and 9400 rpm gas generator speed and at PT5.4 of 40 psia (275.8 kPa) or above, record the following engine parameters at steady-state conditions: (1)

PT5.4 (Power turbine inlet pressure)

(2)

Ps3 (Compressor discharge pressure)

(3)

NGG (Gas Generator Speed)

(4)

P2 (Inlet pressure or barometer - inlet loss)

(5)

T2 (Inlet Pressure)

(6)

HPRCP (High pressure recoup pressure)

b.

Convert all recorded pressure measurements to absolute (psia), and convertall temperature measurements to Fahrenheit.

c.

Using worksheet (figure 3) or spreadsheet (figure 4), calculate whether orifice change is required. NOTE Off schedule variable stator vane (VSV) tracking with resultant NGG effects may make HP recoup orificesize calculation invalid. Ensure VSV schedule is in limits is operating region.

d.

If metering spacer change is required, always install identical orifice size metering spacer at both right and left side locations. Install with metering spacer part number visible from outside. These metering spacers are symmetrical and therfore, nondirectional.

e.

HP recoup metering spacers of less than 0.30 inch (7.6 mm) should not be required or used without prior consultation with manufacturer. CAUTION ALWAYS INSTALL IDENTICAL SIZE METERING SPACER AT BOTH RIGHT AND LEFT SIDE LOCATIONS, WITH IDENTIFICATION NUMBERS VISIBLE. FAILURE TO COMPLY MAY RESULT IN IMPROPER HP RECOUP FUNCTION AND POSSIBLE PART DAMAGE.

f.

Remove four bolts (9, figures 1 and 2) and nuts (8) securing manifold (1) and air tube (2) together.

g.

Remove and replace metering spacer (4) with required size.

h.

Lightly coat four bolt threads and contact faces of bolts (9) and nuts (8) with thread lubricant.




i.

Using four bolts (9) and nuts (8), secure manifold (1) and air tube (2). Tighten nuts to 5570 lb in. (6.3-7.9 N⋅m) of torque.

j.

Recheck orifice calculations at same power setting with new metering spacers installed in order to see if further adjustment is required.

k.

If calculated data or actual HP recoup pressure does not respond to predicted effects of orifice size change, perform the following steps: (1)

Validate data.

(2)

Check for leakage.

(3)

Check gage calibration.

(4)

If substeps (1) through (3) do not correct problem, contact GE Customer Service Representative.




Figure 3. High Pressure Recoup Orifice Selection Worksheet 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 4. Typical Excel Spreadsheet Based on Figure 3. Worksheet 9/(10 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES VARIABLE STATOR VANE SYSTEM INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Variable Stator Vane System Inspection. ..........................................................................

3


1

GEK 105054 Volume II WP 418 00 1.


Introduction. This work package contains instructions for inspection of the variable stator vane (VSV) system.

2.


Number

Operation and Maintenance Manual, Volume I Troubleshooting Operation and Maintenance Manual, Volume II Variable Stator Vane Actuator Replacement Gas Generator Outside Piping and Wiring Removal and Installation Gas Turbine Outside Piping and Wiring Removal and Installation Variable Stator Vane Torque Shaft Replacement Variable Stator Vane Servovalve Replacement Variable Stator Vane Mechanism Replacement High Pressure Compressor Variable Stator Vane Replacement Variable Stator Vane Off-Schedule Inspection


3.


4.

4.Consumable Material.

5.

2

WP 113 00 SWP 113 01 WP 114 00 WP 121 00 WP 209 00 WP 212 00 WP 414 00

Nomenclature


Silicone Rubber Adhesive (RTV-106) Red

GE Spec A15F6B6

Expendable Material. Not required.




Variable Stator Vane System Inspection. a.

Inspect high pressure compressor (HPC) stator case and VSV system per table 1 and figures 1 through 3. Table 1. VSV System Components Inspection

Inspect




1. VSV Servovalve for: a.

Loose cable electrical connectors

Not serviceable

Any amount correctable by replacing or repairing electrical connectors

Replace or repair electrical connectors or replace cable per packager’s manual

b.

External leakage at tube fittings

Not serviceable

Any amount correctable by replacing attaching fitting, preformed packings, or retorquing of fittings

Replace preformed packings or replace servovalve per WP 121 00

c.

Cracked or broken hoses

Not serviceable

Not repairable

Replace hoses

d.

Loose or missing safety wire

Not serviceable

Not repairable

Replace safety wire

e.

Loose or missing hardware

Not serviceable

Any amount correctable by replacing or retorquing hardware

Replace missing hardware or retorque loose hardware

2. VSV Actuator for: a.

Loose cable electrical connectors

Not serviceable

Any amount correctable by replacing or repairing electrical/ cable connectors

Replace electrical cable per WP 113 00 or SWP 113 01

b.

External leakage at tube fittings

Not serviceable

Any amount correctable by replacing attaching fitting, preformed packings, or retorquing of fittings

Replace preformed packings or replace actuator per WP 100 00


3


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. VSV System Components Inspection - (Cont.)

Inspect


2. VSV Actuator for: - (cont.) c. Leakage at 2 cc/min each rod or drain actuator can d.

e.

Loose or missing safety wire Missing or loose mount hardware

Not repairable

On-Site Corrective Action Replace VSV actuator per WP 100 00 or refer to GEK 105054, Chapter 9 Replace safety wire

Not serviceable

Not repairable

Not serviceable

Any amount correctable by replacing or retorquing hardware

Replace missing hardware or retorque loose hardware per WP 100 00

Not repairable

Replace mount bracket per WP 100 00 Retorque mount bolts per WP 100 00 Replace mount bracket per WP 100 00

3. VSV Actuator Mount Bracket for: a. Cracks Not serviceable

b.

Looseness

Not serviceable

Any amount

c.

Distortion

Not serviceable

Not repairable

4. VSV Torque Shaft for: a. Loose Not serviceable hardware b. Missing Not serviceable safety wire c. Bent or Not serviceable distorted input rods 5. VSV Torque Shaft Mounts for: a. Missing Not serviceable safety wire b. Loose Not serviceable hardware c. Cracks or Not serviceable distortion

4


Any amount Not repairable Not repairable

Retorque hardware per WP 114 00 Replace torque shaft per WP 114 00 Replace torque shaft per WP 114 00

Not repairable

Replace safety wire

Any amount

Retorque hardware per WP 114 00 Replace torque shaft per WP 114 00

Not repairable




Inspect




5A. VSV Torque Shaft Bearing for: a.

Fwd bearing

Total movement in the radial direction not to exceed 0.120 in. (3.05 mm). Replace bearings

Not repairable

Replace torque shaft per WP 114 00 and/or upgrade solid shaft to hallow shaft or replace bearing per Service Bulletin LM2500-IND-169

b.

Aft bearing

Total movement in the radial direction not to exceed 0.060 in. (1.52 mm). Replace bearings

Not repairable

Replace torque shaft per WP 114 00 and/or upgrade solid shaft to hallow shaft or replace bearing per Service Bulletin LM2500-IND-169

6. Connector Link for: a.

Cracks

Not serviceable

Not repairable

Replace connector link per WP 209 00

b.

Pinhole wear

Any amount of actuation arm movement less than 2 degrees. Measure per WP 414 00

Not repairable


c.

Wear at rod bearing mount hole

Fit between hole and bolt should not exceed 0.004 in. (0.10 mm) on diameter

Not repairable


d.

Wear at locating pin

0.010 in. (0.25 mm) diameter wire gage shall not pass through hole with pin in place

Not repairable


e.

Loose bolts

Not serviceable

Not repairable

Tighten or replace bolt or replace actuation ring if female thread is stripped per WP 209 00 Change 1


5



Inspect




6. Connector Link for: - (cont.) f.

Nicks, dents, or scratches in link or input rod mount ears


Not repairable


g.

Connector link bushing wear

Not serviceable

Not repairable


7. Actuation Ring Segment for:

6

a.

Nut loose in actuation ring

Not serviceable

_

One spacer per actuation ring segment may be backed off until spacer head is against ring and locked into that position to prevent further wear of actuation ring. Silicone rubber adhesive may be applied around loose nut to stabilize it in ring. See figure 3

b.

Cracks in sidewalls, adjacent to nuts

Any number, 0.040 in. (10.2 mm) max in either direction circumferentially from nut centerline

_

Replace actuation ring segment per WP 209 00

c.

Cracks in ID and OD wall, between nut and end of ring

Two per end, from first nut to end of ring, if nut is tight and will not rotate

_


d.

All other cracks

Not serviceable

Not repairable





Inspect




7. Actuation Ring Segment for: - (cont.) e.

Broken

Not serviceable

Not repairable

See Off-Schedule Variable Vane Inspection, WP 414 00

f.

Pinhole elongation

Any amount of actuation arm movement less than 2 degrees. Measure per WP 414 00

Not repairable

See Off-Schedule Variable Vane Inspection, WP 414 00

g.

Wear at hole of actuation ring spacer threaded insert

Relative motion between insert and ring segment shall not exceed 0.005 in. (0.12 mm). Use wire gage

Not repairable


h.

Wear of hole at metal bushing

Relative movement between insert and ring segment shall not exceed 0.005 in. (0.12 mm). Use wire gage

Not repairable


i.

Distortion (bent or twisted)

Not serviceable

Not repairable


j.

Nicks and dents

Any number, 0.015 in. (0.38 mm) deep, six per segment, or 0.030 in. (0.76 mm) deep, with a minimum separation of 2.00 in. (50.8 mm)

Not repairable



7



Inspect




8. Actuation Ring Spacer for: a.

Loose or out of adjustment (Dim M, figure 1)

Not serviceable

Any amount

Adjust to obtain case to spacer clearance per WP 209 00

9. Vane Arm Sleeve for: a.

Worn

Nor serviceable

Not repairable


b.

Missing

Nor serviceable

Not repairable


c.

Cracked

Nor serviceable

Not repairable


Radial looseness: Any amount of radial movement, if bushings or washers are not missing. No metal-to-metal contact allowed

-

Remove case and replace bushings if metal-to-metal contact is noted

Side looseness: Any amount of side looseness 2 degrees or less. Measure per WP 414 00

-

See WP 414 00

10. Vane Assembly for (See figure 2.): a.

8

Looseness

b.

Bent actuation arms

Any number, bent 2 degrees or less. Measure per WP 414 00

-

See WP 414 00

c.

Misassembled actuation arms

Not serviceable

-

See WP 414 00




Inspect




11. Vane Locking Nut for: a.

Looseness

Nut shall be tight, with at least three vane stud threads showing, as determined visually

Any amount

Replace nut if runon torque is less than 5 lb in. (0.6 N⋅m). If more than 5 lb in. (0.6 N⋅m), retorque nut to 86-95 lb in. (11.4-12.6 N⋅m). If locking nut is missing, see WP 414 00

b.

Loss of selflocking feature

5-40 lb in. (0.6-4.5 N⋅m) free running torque

Not repairable

Replace locking nut per WP 212 00

c.

Thread damage

Not serviceable

Not repairable

Replace locking nut per WP 212 00

12. Vane Actuation Arm for: a.

Security

Actuation arm shall be in place and secure

Any amount, if nut is in place and actuation arm is engaged in trunnion

Replace nut and tighten. If nut was not in place, see WP 414 00

b.

Distortion, bending, or pinhole elongation

Any amount, less than 2 degrees. Measure per WP 414 00

Not repairable

See WP 414 00

c.

Cracks

Not serviceable

Not repairable

Replace actuation arm

d.

Bent, distorted, or misaligned. Measure per WP 414 00

Not serviceable if more than ± 2 degrees

Not repairable

See WP 414 00


9


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. VSV System Components Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect



13. Spacer for: a.

Cracks

Not serviceable

Not repairable

Replace spacer

Shake vane while holding nut and listen for metal-tometal contact

Not repairable

Replace bushing

14. Glass Bushing for: a.

Wear

Figure 1. VSV Actuation Ring Spacer Dimension M

10




Figure 2. VSV Actuation System (Sheet 1 of 3) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

11



Figure 2. VSV Actuation System (Sheet 2 of 3) 12




Figure 2. VSV Actuation System (Sheet 3 of 3) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

13



Figure 3. Actuation Ring Spacer Nut Stabilized with RTV

14




WORK PACKAGE

TECHNICAL PROCEDURES THERMOCOUPLE PROBE (T5.4) INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Thermocouple Probe (T5.4) Inspection...............................................................................

3


GEK 105054 Volume II WP 419 00 1.


Introduction. This work package provides instructions for the inspection of the T5.4 thermocouple probe.

2.

3.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Thermocouple Probe (T5.4) and Harness Replacement

GEK 105054 WP 002 00 WP 108 00



Multimeter

Local Purchase

4.


5.





Thermocouple Probe (T5.4) Inspection. a.


b.

Remove thermocouple harness from thermocouple probe per WP 108 00. NOTE Thermocouple probe may be left in turbine mid frame as long as probe junction is at 70°F (21.1°C).

c.

Remove thermocouple probe from turbine mid frame (TMF) per WP 108 00.

d.

Using multimeter, measure resistance across posts. Resistance from point A to point B (figure 1) shall be 0.44-0.83 ohms at 70°F (21.1°C). Discard thermocouple probes that do not meet specified reading.

e.

Using multimeter, measure resistance between posts and case. Resistance shall not be greater than 10 megohms.

f.

Install thermocouple probe into TMF per WP 108 00.

g.

Install thermocouple harness onto thermocouple probe per WP 108 00.

Figure 1. T5.4 Thermocouple Probe 3/(4 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES ACCESSORY GEARBOX INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Accessory Gearbox Inspection. ........................................................................................... Accessory Gearbox Part Repair. ......................................................................................... Accessory Gearbox Part Replacement................................................................................

3 3 3


GEK 105054 Volume II WP 420 00 1.


Introduction. This work package provides instructions for the inspection and repair of the LM2500+ Models GK and GV gas generator and Models PK and PV gas turbine accessory gearbox (AGB).

2.


Number

Operation and Maintenance Manual, Volume II Accessory Gearbox Replacement Illustrated Parts Breakdown

GEK 105054 WP 206 00 GEK 105055

3.


4.


5.


IPB Figure No./Item

Expandable Bushing Assembly

6-44




7.

Accessory Gearbox Inspection. a.

Remove AGB per WP 206 00.

b.

Inspect high pressure compressor (HPC) stator casing mounts and AGB mounting hardware per table 1 and figure 1.

Accessory Gearbox Part Repair. a.

8.

Part repair is limited to blending, cleaning, and replacing as noted during inspection.

Accessory Gearbox Part Replacement. a.

See table 1 for HPC stator casing mounts and mounting hardware replacement. Table 1. HPC Stator Casing Mounts and Mounting Hardware

Inspect




1. HPC Stator Casing Mounts (1, figure 1) for: a.

Cracks

Not serviceable

Not repairable

Replace bracket*

b.

Nick, scores, and scratches

Not serviceable

Any number, 0.062 in. (1.5 mm) deep, 0.50 in. (12.7 mm) long, if length of damage does not exceed 4.00 in. (101.6 mm)

Completely blend out defect

c.

Pickup and high metal on mating surfaces

Not serviceable

Any amount

Remove high metal

d.

Thread for damage

Not serviceable

One complete internal thread may be missing

Replace insert

e.

Missing or loose paint

Not serviceable

Any amount

Remove loose paint.

f.

Bushing hole wear

0.725 in. (18.41 mm) ID max

Not repairable

Replace bushing



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. AGB Mounting Support and Mounting Hardware - (Cont.)

Inspect


2. Forward TGB Mounting Bracket (8) for: a. Cracks Not serviceable b. Nicks, scores, Not serviceable and scratches

c.



Not repairable Any number, any length, 0.02 in. (0.5 mm) deep, after removal of high metal and blending Not repairable

Replace bracket* Remove high metal and blend to remove damage

Clevis hole 1.015 in. Replace bracket* wear (25.78 mm) ID 3. Right and Aft Mounting Bracket Assemblies (5 and 6) for: a. Cracks Not serviceable Not repairable Replace bracket* b. Nicks, scores, Not serviceable Any number, any Remove high metal and scratches length, 0.0625 in. and blend to remove (1.587 mm) deep, damage after removal of high metal and blending c. Flanged 0.005 in. (0.12 mm) Not repairable Replace bracket* bushing hole ID wear 4. Adjustable Link Assemblies (2 and 4) and Fixed Link Assembly (3) for: a. Cracks Not serviceable Not repairable Replace part* b. Link rod-end Not serviceable Any amount, if Clean and uniball for uniball is rust-free inspect seizure and swivels freely with finger-pressure after cleaning c. Link rod-end 0.005 in. (0.12 mm) Not repairable Replace rod-end uniball for radial clearance, assembly* wear 0.010 in. (0.25 mm) axial clearance d. Rod-end Not serviceable Cumulative length of Remove damage by thread 1/2 full thread may chasing thread damage be removed e. Turnbuckle Not serviceable Not repairable Replace part* distortion



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. AGB Mounting Support and Mounting Hardware - (Cont.)

Inspect




4. Adjustable Link Assemblies (2 and 4) and Fixed Link Assembly (3) for: - (cont.) f.

Turnbuckle thread damage

Not serviceable

Cumulative length of 1/2 full thread may be removed

Remove damage by chasing thread

g.

Turnbuckle nicks, dents, or scratches


Not repairable

Replace part*

5. Expandable Bushing (7) for: a.

Shear bolt shank wear

0.0005 in. (0.012 mm) OD, min in contact area

Not repairable

Replace bolt*

b.

Shear bolt and nut thread damage

Not serviceable

Not repairable

Replace part*

c.

Loss of nut self-locking feature

Not serviceable

Not repairable

Replace nut*

d.

Wear of Not serviceable Not repairable expandable bushing * May be repairable. Contact GE for disposition of replaced parts.

Replace part*




Figure 1. AGB and Mounting Components 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES SIX STAGE POWER TURBINE COMPONENTS INSPECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 13.................. 0 14 Blank ........... 0 Alphabetical Index Page

Subject Power Turbine Stator Casings Inspection. ........................................................................ Turbine Rear Frame - Component Inspection. ..................................................................

3 9


GEK 105054 Volume II WP 421 00 1.


Introduction. This work package provides instructions for the inspection of power turbine components.

2.


Number

Operation and Maintenance Manual, Volume II Six Stage Power Turbine Stator Casings Removal and Installation Power Turbine Assembly Replacement

GEK 105054

3.


4.


5.


WP 218 00 WP 302 00




Power Turbine Stator Casings Inspection. a.

Remove power turbine stator casings per WP 218 00.

b.

Inspect power turbine casings per figure 1 and table 1.

c.

Install power turbine stator casing per WP 218 00. Table 1. Power Turbine Stator Casings Inspection

Inspect




CASING 1. Front Flange for: a.


Not serviceable

Replace power turbine per WP 302 00*

b.

Cracks, not extending from boltholes

Any number, 0.016 in. (0.40 mm) long, with 2.0 in. (50.8 mm) min spacing between cracks


c.

Nicks and scores


Blend



Not serviceable


b.


2 cracks per flange, if adjacent holes not cracked




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Stator Casings Inspection - (Cont.)

Inspect




2. Rear Flange for: - (cont.) c.


Any number, any length 0.031 in. (0.78 mm) deep, not extending across more than 75 percent of flange face, after removal of high metal

Blend

3. Horizontal Flanges for: a.


2 cracks per flange, if mating flange on other half of casing does not have cracks at same holes


b.



Blend

4. Casing Body (Except for vane mounting tracks) for: a.

Cracks

Any number, 0.062 in. (1.57 mm) long with 2.0 in. (50.8 mm) in spacing


b.

Nicks



c.

Scratches






Inspect




4. Casing Body for: (Except for vane mounting tracks) for: - (cont.) d.

Dents

Any number, 0.125 in. (3.17 mm) deep, if assembly can be accomplished


e.

Distortion

Free state distortion acceptable, if assembly can be accomplished


5. Vane Mounting Tracks a.

Cracks

Not serviceable

b.

Nicks and scratches

Not serviceable

c.

Dents and distortion

Any amount, if vane can be installed

Replace power turbine per WP 302 00* Any amount

Blend

INTERSTAGE SEALS 1. Flange for: a.

Deformation

Not serviceable

Replace segment or replace power turbine per WP 302 00*

b.

Cracks or breakout at boltholes

Not serviceable


c.

Cracks

Not serviceable


d.



Blend




Inspect




0.005 in. (0.12 mm) deep

0.010 in. (0.25 mm) deep

Blend smooth

1. Flange for: - (cont.) e.

Wear

2. Honeycomb for: a.

Wear

Track not to exceed 0.150 in. (3.81 mm) max depth

Not repairable

Replace segment

b.

Damage caused by foreign objects or handling

Not to exceed 0.170 in. (4.31 mm) axially from forward edge or 10 percent of total circumferential length of stage, if damage does not extend into backing strips and there are no folded edges in honeycomb cells

Folded edges may be removed in any area of honeycomb up to 100% of each shroud segment

Remove folded edges of crushed cells

c.

Loose or missing cells

Not serviceable, except outer row of cells may be missing from both forward and aft edges, if there are no loose cells

Any amount of loose cells in forward and aft outer rows. On remainder of segment, 5 adjacent cells and no more than 3 such areas per segment

Remove loose cells

d.

Erosion of filler material

Any amount, as long as cells are still bonded

Not repairable

Replace segment

e.

Damage to extended honeycomb (stages 1, 2, and 3)

Any amount crushed even with backing strip and not loose

One cell row inside backing strip edge and 1/2 axial width

Remove loose metal




Inspect




3. Braze Joints for: a.

Cracks

Any number, 0.0625 in. (1.58 mm) long, 0.125 in. (3.17 mm) min spacing

Replace segment

SHROUDS l. Honeycomb for: a.

Wear

Track not to exceed 0.100 in. (2.5 mm) max depth

Not repairable

Replace segment

b.


Not to exceed 10 percent of total circumferential length and not extending into backing strip if there are no folded edges on cells

Folded edges may be removed in any area of honeycomb up to 10% of each shroud segment

Remove folded edges of crushed cells

c.

Loose or unbonded cells

Not serviceable

5 adjacent cells and no more than 2 such areas per segment

Remove cells

d.

Erosion of braze filler material

Any amount, as long as cells are still unbonded

Not repairable

Replace segment

STAGE 1 NOZZLE INSULATOR COVER SEGMENTS 1. All Surfaces for: a.

Cracks

b.

Distortion


Not repairable

Replace segments

Any amount, if Replace segments assembly can be accomplished * May be repairable, consult GE for disposition of replaced parts.




n

Figure 1. Power Turbine Stator Assembly 8 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Turbine Rear Frame - Component Inspection. a.

Inspect turbine rear frame (TRF) per figure 2 and table 2. Table 2. Turbine Rear Frame Inspection

Inspect




NOTE Indications in parent metal (outside a weld/heat affected zone) are acceptable if the following conditions are met:· Indications are spaced greater than 0.50 inch (12.7 mm) apart.· Indications up to 0.030 inch (0.76 mm) long.· Indications 0.030-0.060 inch (0.77-1.52 mm) long, not interpreted as cracks. CASE 1. All Surfaces (unless otherwise specified) for: a.

Parent metal cracks

Not serviceable

Weld repairable in stiffening ribs, not repairable all other areas

Weld-repair stiffening ribs or replace power turbine per WP 302 00*

b.

Weld cracks

Any number, 0.062 in. (1.57 mm) long, if separation between cracks is 0.50 in. (12.7 mm)

Weld repairable in stiffening ribs, not repairable all other areas

Weld-repair stiffening ribs or replace power turbine per WP 302 00*

c.


Any number, any length 0.016 in. (0.40 mm) deep, after removal of high metal, if they do not extend completely across sealing surface(s)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. Turbine Rear Frame Inspection - (Cont.)

Inspect




2. Fore and Aft (Bolt Circle) Flanges for: a.

Cracks

2 boltholes, 180 degrees apart

Not repairable


b.

Deformation

Not serviceable

Not repairable


3. D-Sump Manifold Mounting Pad (Strut No. 5) for: a.

Seating surface nicks, scores, and scratches

Any number, any length, 0.016 in. (0.40 mm) deep, after removal of high metal. Defects shall not extend completely across sealing surface

Not repairable


b.

Damaged threads

Not serviceable

Not repairable


4. Overspeed Transducer Mounting Flanges for: a.

Cracks

Not serviceable

Not repairable


b.

Deformation

Not serviceable

Not repairable


5. Clevis Mounts (Power Turbine) for: a.

Cracks

Not serviceable

Not repairable


b.

Bushing wear

Not serviceable

Not repairable





Inspect




5. Clevis Mounts (Power Turbine) for: - (cont.) c.


Any number, any length, 0.016 in. (0.40 mm) deep, after removal of high metal. Defects shall not extend completely across sealing surface(s)

Not repairable


d.

Dents

Any number, smooth contour dents 0.250 in. (6.35 mm) deep

Not repairable


6. Strut Fairing for: a.

Loose or missing rivets

Not serviceable

Any amount

Replace missing rivet(s)

b.

Cracks

Not serviceable

Not repairable


HUB 1. All Surfaces for: a.

Parent metal cracks

Not serviceable

Not repairable


b.

Weld cracks

Not serviceable

Not repairable


c.


Any number, any length, 0.016 in. (0.40 mm) deep, after removal of high metal. Defects shall not extend completely across sealing surface(s)

Not repairable





Inspect




2. Hub to Sump Housing Flange Bolts for: a.

Loose or missing bolts and nuts

Not serviceable

Any number

Tighten or replace missing bolt and nut

Any number

Tighten screw. Screw shall be flush or below face of flange

3. Hub Gang Channels (Nut Assembly) for: a.

High or loose retaining screws

Not serviceable

* May be repairable, consult GE for disposition of replaced parts.




Figure 2. Turbine Rear Frame Subassembly Cutaway 13/(14 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES SIX STAGE POWER TURBINE STAGES 1 AND 6 ROTOR BLADE INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Power Turbine Rotor Blade Inspection. .............................................................................

3


1

GEK 105054 Volume II WP 422 00 1.


Introduction. This work package contains instructions for inspection of the LM2500+ Model PK gas turbine six stage power turbine stages 1 and 6 rotor blades.

2.

3.


Number

Operation and Maintenance Manual, Volume II General Maintenance Practices Thermocouple Probe (T5.4) and Harness Replacement Power Turbine Inlet Pressure Probe (P5.4) Replacement Six Stage Power Turbine Casings Removal and Installation Six Stage Power Turbine Stage 1 Rotor Blade Replacement Power Turbine Assembly Replacement

GEK 105054 WP 002 00 WP 108 00 WP 112 00

WP 219 00 WP 302 00


Part No.

Borescope, Rigid Borescope, Flexible

2C6388G06 856A1321

4.


5.


2

WP 218 00




Power Turbine Rotor Blade Inspection. a.

Comply with all instructions contained in WP 002 00. NOTE Power turbine rotor stage 2 through stage 5 blades are not accessible for inspection without removal of power turbine stator casings.

b.

Inspect power turbine stage 1 rotor blades as follows: (1)

Prepare turbine mid frame (TMF) for borescope as follows: (a) Remove P5.4 pressure probe per WP 112 00. (b) Remove T5.4 thermocouples per WP 108 00. NOTE

Power turbine stage 1 rotor blade shroud inspection is not possible via borescope inspection. (2)

Using borescope, inspect power turbine stage 1 rotor blades. Manually rotate power turbine rotor to inspect of all stage 1 blades. Inspect power turbine stage 1 rotor blades per table 1 and figure 1.

(3)

If inspection of power turbine stage 1 rotor blade shrouds is required, proceed as follows: (a) Remove power turbine stator casings to expose power turbine rotor per WP 218 00. (b) Inspect power turbine stage 1 rotor blade shrouds per table 1 and figures 1 through 3.

c.

(4)

If removed, install P5.4 pressure probe per WP 112 00.

(5)

If removed, install T5.4 thermocouple probes per WP 108 00.

(6)

If removed, install power turbine stator casings per WP 218 00.

Inspect power turbine stage 6 rotor blades per following: (1)

Gain access to power turbine exhaust area per packager’s manual.

(2)

Visually inspect power turbine stage 6 rotor blades per table 1 and figures 1 through 3.

(3)

Inspect power turbine stage 6 rotor blade retainers per table 1 and figure 4.

(4)

Install exhaust duct access hatch per packager’s manual. Change 1


3


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Rotor Blades

Inspect




POWER TURBINE STAGE 1 ROTOR BLADES 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace power turbine blade per WP 219 00

2. Leading and Trailing Edges for: a.

Nicks

Areas X and Y: none. Balance of blade: any number, 0.04 inch (1.0 mm) deep; minimum separation of 0.5 inch (13 mm)

Not repairable


b.

Dents

Any number with no protrusions on opposite side. Five per blade with protrusion not to exceed 0.04 inch (1.0 mm) on opposite side

Not repairable


c.


Entire blade: trace of surface corrosion acceptable

Missing material: not repairable


3. Concave and Convex Surfaces for:

4

a.

Nicks

Areas X and Y: none. Balance of blade: any number, 0.04 inch (1.0 mm) deep; minimum separation 0.25 inch (6.4 mm)

Not repairable


b.

Dents

Any number, with no protrusion on opposite side

Not repairable


c.


Entire blade: trace of surface corrosion acceptable

Extensive corrosion: not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Rotor Blades - (Cont.)

Inspect




POWER TURBINE STAGE 1 AND STAGE 6 ROTOR BLADE SHROUDS 1. Blade Shrouds for: a.

Overlapping

Any number, provided blade has not shifted axially

Any number may be relatched


Unlatching

Any number, provided blade has not shifted axially

Any number may be relatched


Interlock wear

0.020 inch (0.51 mm)

0.100 inch (2.54 mm)


POWER TURBINE STAGE 6 ROTOR BLADES 1. All Areas for: a.

Cracks

Not serviceable

Not repairable


2. Leading and Trailing Edges for: a.

Nicks

Areas X and Y: same as balance of blade. Balance of blade: any number, 0.04 inch (1.0 mm) deep; minimum separation of 0.5 inch (13 mm)

Not repairable


b.

Dents

Areas X and Y: same as balance of blade. Balance of blade: any number with no protrusions on opposite side. Five per blade with protrusion not to exceed 0.04 inch (1.0 mm) on opposite side

Not repairable



5


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Power Turbine Rotor Blades - (Cont.)

Inspect




2. Leading and Trailing Edges for: - (cont.) c.


Areas X and Y: same as balance of blade. Balance of blade: any amount

3. Concave and Convex Surfaces for: a.

Nicks

Areas X and Y: same as balance of blade. Balance of blade: any number, 0.04 inch (1.0 mm) deep; minimum separation 0.25 inch (6.4 mm)

Not repairable


b.

Dents

Areas X and Y: same as balance of blade. Balance of blade: any number, with no protrusion on opposite side

Not repairable


c.


Areas X and Y: same as balance of blade. Balance of blade: any amount

BLADE RETAINERS 1. Stage 6 Blade Retainers for: a.

Unbending

Not to exceed 30 degrees away from blade

Not repairable


b.

Axial movement, forward or aft

0.100 inch (2.54 mm)

Not repairable


* May be repairable. Consult GE for disposition of replaced parts.

6




Figure 1. Power Turbine Blade Inspection Areas Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

7



Figure 2. Power Turbine Blade Shrouds 8




Figure 3. Power Turbine Rotor Blade Shroud Inspection Areas Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

9



Figure 4. Stage 6 Power Turbine Blade Retainer Inspection Criteria 10




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR STATOR CASINGS INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Compressor Stator Casings Inspection. ....................................................

3


GEK 105054 Volume II WP 423 00 1.


Introduction. This work package provides instructions for inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, high pressure compressor (HPC) stator casings.

2.


Number

Operation and Maintenance Manual, Volume II High Pressure Compressor Stator Casings Replacement High Pressure Compressor Variable Stator Vane Replacement High Pressure Compressor Fixed Stator Vane Replacement

GEK 105054 WP 211 00

3.


4.


5.


WP 212 00 WP 214 00




High Pressure Compressor Stator Casings Inspection. a.

Remove HPC stator casings per WP 211 00.

b.

Remove variable stator vanes (VSV) per WP 212 00.

c.

Remove fixed stator vanes per WP 214 00.

d.

Inspect forward HPC stator casings per table 1 and figure 1.

e.

Inspect aft HPC stator casing per table 1 and figure 2. Table 1. HPC Stator Casings And Components

Inspect


HPC FORWARD STATOR CASE 1. Horizontal Flanges for: a. Cracks Not serviceable, except; max of 3 per flange per casing half, emanating from boltholes outward to edge of flange b. Nicks, Any number, 0.015 scratches, in. (0.38 mm) deep, dents, or if defect does not gouges on extend completely mating across mating surface flange 2. Circumferential Flanges for: a. Cracks Not serviceable, except; max of 3 per flange per casing half, emanating from boltholes outward to flange outside dia (OD), one per hole



Not repairable

Replace HPC stator casings as matched set per WP 211 00*


Remove high metal

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.) On-Site Maximum Serviceable Limits

Inspect

2. Circumferential Flanges for: - (cont.) b. Nicks, Any number, 0.015 scratches, in. (0.38 mm) deep, dents, and if defect does not gouges extend completely across mating surface 3. Casing ID Surface for: a. Cracks Not serviceable

b.

Rotor rub marks

0.025 in. (0.63 mm) deep. Coating shall be fully bonded in all areas.




Remove high metal

Not repairable

Replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*

Not repairable

NOTE Perform following measurements after removal of metal buildup. c.

Rotor rub into parent metal

1. Any amount to 0.010 in. (0.25 mm) deep or 0.055 (1.39 mm) remaining wall thickness in area from forward flange to stage 7 vane slot 2. Any amount to 0.020 in. (0.50 mm) deep in area from stage 7 vane slot to aft flange

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC Stator Casings And Components - (Cont.)

Inspect


3. Casing ID Surface for: - (cont.) d. Nicks and Any number, 0.025 scratches in. (0.63 mm) deep, 1.0 in. (25.4 mm) long. Max of 10, 0.025 in. (0.63 mm) deep, any length e. Gouges on Any number, 0.010 areas between in. (0.25 mm) deep, T-slots and 0.25 in. (6.3 mm) around vane long bores f. Spalling or Up to 5.0 square in. chipping of (32 cm2) per abradable rub stage missing, if adjacent remaining coat material is fully bonded to parent metal (no evidence of peeling). Any amount of coating may be missing in area 4.603 in. (116.91 mm) from face of front flange 4. Variable Vane Bore Mating Surfaces for: a. Nicks and 0.010 in. (0.25 mm) scratches deep, if not over 30 percent of area is affected, and not over 50 percent of vane bores in each stage are affected and after removal of high metal


On-Site Corrective Action Remove high metal

Any number 0.020 in. (0.50 mm) deep, 0.25 in. (6.3 mm) long

Remove high metal

Not repairable


0.0312 in. (0.792 mm) deep, if not over 20 percent of area is affected, and not over 50 percent of vane bores in each stage are affected.





Inspect

5. Mounting Pads for: a. Insert Not serviceable damage 6. Manifold (Stage 9) for: a. Cracks Not serviceable

b

Dents

3 per casing half, 0.25 in. (6.3 mm) deep, with min spacing of 2.0 in. (50.8 mm), and at least 0.75 in. (19.0 mm) from any weld. 0.050 in. (1.27 mm) min radius at bottom of dent 7. Casing Externally for: a. Cracks in ribs Not serviceable (excluding manifold ribs)



Any number

Replace insert

Not repairable


Not repairable

3 per casing, 0.5 in. (12.7 mm) long, if spacing between each defect exceeds 3.0 in. (76.2 mm)

Bench with 0.030 in. (0.76 mm) min radius tool to max depth of 0.0156 in. (0.396 mm) and inspect, or replace HPC stator casings as matched set per WP 211 00*




Inspect

7. Casing Externally for: - (cont.) b. Cracks in Not serviceable casing skin



Any number, 0.5 in. (12.7 mm) long, if spacing between each defect exceeds 3.0 in. (76.2 mm)

Bench with 0.030 in. (0.76 mm) min radius tool to max depth of 0.0156 in. (0.396 mm) and inspect. No indications allowed, or replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*

c.

Bulges

Not serviceable

Not repairable

d.

Pits

Not repairable

e.

Nicks or scratches

Any number, up to 0.125 in. (3.17 mm) diameter and 0.0156 in. (0.396 mm) deep Any number, 0.0156 in. (0.396 mm) deep 1.0 in. (25.4 mm) long, with 0.030 in. (0.76 mm) min radius at bottom except in area of vane T-slots where remaining casing thickness shall not be less than 0.060 in. (1.52 mm) at stage 10 and 0.090 in. (2.28 mm) at stage 11

Any number, 0.030 in. (0.76 mm) deep, 1.5 in. (38.1 mm) long, with 0.030 in. (0.76 mm) min radius at bottom except in area of vane T-slots where remaining casing thickness shall not be less than 0.060 in. (1.52 mm) at stage 10 and 0.090 in. (2.28 mm) at stage 11

Remove high metal. Blend out nicks or scratches with 0.030 in. (0.76 mm) min radius tool, or replace HPC stator casings as matched set per WP 211 00*




Inspect


7. Casing Externally for: - (cont.) f. Local surface Not serviceable discoloration (blue) due to blade tip rub g. Wear cause by 0.025 in. (0.63 mm) actuation ring deep, after removal spacer of high metal and sharp edges KEY 1. HPC Upper Stator Casing Key for: a. Damage Any amount, if proper assembly can be performed and key does not protrude above casing flange HPC AFT STATOR CASE 1. Horizontal Flanges for: a. Cracks Not serviceable except max of one per flange per casing half emanating outward from boltholes to flange edge b. Nicks, dents, Any number to scratches, and 0.0312 in. (0.792 gouges mm) deep, after removal of high metal, if defect does not completely cross mating surface



Not repairable

Replace HPC stator casings as matched set per WP 211 00

Not repairable


Not repairable

Replace part

Not repairable


Remove high metal with fine emery cloth or replace casings as matched set*




Inspect


2. Forward and Aft Circumferential Flanges for: a. Cracks Not serviceable Not repairable

b.

Any number to 0.0312 in. (0.792 mm) deep, after removal of high metal, if defect does not completely cross mating surface 3. Casing ID Surface for: a. Cracks Not serviceable

b.

c.

d.

Nicks, dents, scratches, and gouges

Not repairable

Nicks, scratches, scores, or gouges on vane retaining lips and lands Rotor rub marks

Any number 0.0312 in. (0.792 mm) deep, after removal of high metal

Not repairable

Any amount, if bond coat still remaining

Not repairable

Spalling or chipping of abradable rub coat

Any amount within 0.125 in. (3.17 mm) of edge and 10 percent of remaining area

Not repairable

On-Site Corrective Action Replace HPC stator casings as matched set per WP 211 00* Remove high metal with fine emery cloth or replace HPC stator casings as matched set per WP 211 00*

Replace HPC stator casings as matched set per WP 211 00* Remove high metal with fine emery cloth, or replace HPC stator casings as matched set per WP 211 00* Remove high metal with fine emery cloth, or replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*




Inspect

3. Casing ID Surface for: - (cont.) e. Gouges on 1.0 square in. (6.5 area other cm2) per circumferential than fixed land vane retaining lips

4. Casing Externally for: a. Cracks in skin Not serviceable

b.

Nicks, scratches, and dents

c.

Bulges

Any number, 0.25 in. (6.3 mm) long, 0.0156 in. (0.396 mm) deep, after removal of high metal Not serviceable

5. Manifold (Stage 13) for: a. Cracks in Not serviceable weld or parent metal b. Nicks and Any number to scratches 0.0156 in. (0.396 mm) deep



One gouge 0.035 in. (0.88 mm) deep, 1.0 in. (25.4 mm) long per stage per casing half, and 3 gouges, 0.015 in. (0.38 mm) deep, 6.0 in. (152.4 mm) long per stage casing half

Remove high metal

Not repairable

Replace HPC stator casings as matched set per WP 211 00* Bench with 0.030 in. (0.76 mm) min radius tool or replace HPC stator casings as matched set per WP 211 00* Replace HPC stator casings as matched set per WP 211 00*

Not repairable

Not repairable

Not repairable





Inspect


5. Manifold (Stage 13) for: - (cont.) c. Dents 3 per casing half, 0.25 in. (6.3 mm) deep, 2.0 in. (50.8 mm) apart and at least 0.75 in. (19.0 mm) from any weld with min radius of 0.050 in. (1.27 mm) at bottom of dent KEY 1. HPC Upper Stator Casing Key for: a. Damage Any amount, if proper assembly can be performed and key does not protrude above casing flange



Not repairable


Not repairable

Replace part

*May be repairable, consult GE for disposition of replaced parts.




Figure 1. HPC Forward Stator Casing 12 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. HPC Aft Stator Casing 13/(14 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR ROTOR INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 16 ................. 0


Page

High Pressure Compressor Rotor Inspection..................................................................... 3 High Pressure Compressor Rotor Blade General Repair.................................................. 7 High Pressure Compressor Rotor Blisk and Stage 1 Blade Repair.................................. 11 High Pressure Compressor Stage 2 Blade Repair. ............................................................ 13 High Pressure Compressor Stages 3 through 16 Blade Repair. ....................................... 15


GEK 105054 Volume II WP 424 00 1.


Introduction. This work package provides instructions for inspecting the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, high pressure compressor (HPC) rotor.

2.


Number

Operation and Maintenance Manual, Volume II High Pressure Compressor Stator Casings Replacement High Pressure Compressor Rotor Blades Replacement

GEK 105054 WP 211 00 WP 215 00

3.


4.


5.





High Pressure Compressor Rotor Inspection. a.

Expose HPC rotor per WP 211 00.

b.

Refer to table 1 and figure 1 for inspection limits. Table 1. Compressor Spools, Disks, and Blades On-Site Maximum Serviceable Limits

Inspect

SPOOLS AND DISKS 1. All Areas for: a. Cracks Not serviceable (except seals) 2. Front Air Seal Serration for: a. Pits, nicks, Not serviceable dents, and scratches b.

Bending

Not serviceable

3. Interstage Air Seal Serrations for: a. Pits, nicks, Any number, 0.005 dents, and in. (0.12 mm) deep. scratches Any number, 0.03 in. (0.76 mm) deep, 0.050 in. (1.27 mm) long, separated by 15 degrees and 5 degrees from blends on adjacent teeth b. Bending Not serviceable



Not repairable

Replace gas generator

Five per tooth. Total areas removed, not to exceed 0.15 sq. in. (0.96 cm2) per tooth Five per tooth. Total areas removed, not to exceed 0.15 sq. in. (0.96 cm2) per tooth

Blend

Three per 6.00 in. (152.4 mm) of circumference on each tooth, 0.090 in. (2.28 mm) deep, 0.050 in. (1.27 mm) long

Blend

One per tooth, 1.00 in. (25.4 mm) long


Blend



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Spools, Disks, and Blades - (Cont.) On-Site Maximum Serviceable Limits

Inspect



4. Journal OD for: a.


Any number, 0.020 in. (0.50 mm) wide, 0.003 in. (0.07 mm) deep, after removal of high metal


Remove high metal

5. Oil Seal Serrations for: a.

Nicks and dents on OD

Not serviceable

Five per each serration, 0.045 in. (1.14 mm) deep, 0.50 in. (12.7 mm) long after blending. One serration, 1.00 in. (25.4 mm) long for depth of serration

Blend

b.

Cracks originating from OD

Not serviceable

Five per each serration, depth of serration

Blend. Width of blend to be two times depth of crack

Not serviceable

Threads shall be free of all pickup metal. Cumulative length of 50% complete thread can be removed

Remove pickup metal. Blend to original finish

0.19 square in. (1.2 cm2), not extending into flow path

Blend off bent up corners. Do not leave thin edge. Break all thin edges and blend smooth

6. External Threads for: a.

Damage

7. Stages 1 and 2 Disk OD Airflow Surface for: a.

Tang corner tip curl

0.13 square in. (0.83 cm2), not extending into flow path

8. OD Surfaces, Stages 3 through 13, Abradable Rub Coat for: a.

Missing spray coating

Any amount

-

-

b.

Vane rub

Any amount, if parent metal is not rubbed

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Compressor Spools, Disks, and Blades - (Cont.) On-Site Maximum Serviceable Limits

Inspect



9. OD Surfaces, Stages 14 through 16, Abradable Rub Coat for: a.

Vane rub, nicks or scores, and scratches between stages 13 and 14

Any amount, if parent metal is not rubbed and not exceeding 0.005 in. (0.12 mm) depth per stage

Not repairable


b.

Vane rub, nicks or scores, and scratches

Any amount, if parent metal is not rubbed and not exceeding 0.005 in. (0.12 mm) depth per stage

Not repairable


10. OD Surfaces, Other than Abradable Rub Coat, for: a.

Pits, nicks, scores, and scratches

Any number, 0.003 in. (0.07 mm) deep, if not more than 25 percent of total area is affected

-

-


Any number, 0.005 in. (0.12 mm) deep. Up to 25 percent of area may be blended

Blend

11. All Other Surfaces: a.

Pits, nicks, scores, and scratches

HIGH PRESSURE COMPRESSOR ROTOR BLADES 1. Repair damage to airfoils to limits specified in paragraphs 7, 8, 9, and 10 of this work package. For damage/wear to all other areas of blade, replace blade.




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



High Pressure Compressor Rotor Blade General Repair WARNING TITANIUM DUST IS A FIRE HAZARD. KEEP FLAMES AND SPARKS AWAY FROM WORK AREA. DISPOSE OF DUST IN APPROVED CONTAINERS. KEEP A SUITABLE COMPOUND AVAILABLE FOR EXTINGUISHING CLASS D FIRES. DO NOT USE WATER. IN AN EMERGENCY, DRY SAND CAN BE USED AS A FIRE FIGHTING AGENT. CAUTION TITANIUM PARTS SHALL NOT BE BLEND REPAIRED WITH TOOLS SUCH AS GRINDING WHEELS, FILES, STONES, OR EMERY CLOTHS THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DO NOT USE SILVER OR CADMIUM TOOLS ON TITANIUM PARTS. WHEN CADMIUM- OR SILVER-PLATED TOOLS ARE USED ON TITANIUM PARTS, PARTICLES OF CADMIUM OR SILVER MAY BECOME EMBEDDED IN TITANIUM. AT TEMPERATURES ABOVE 500°F (316°C), METALS CAN CAUSE EMBRITTLEMENT, RESULTING IN OVERSTRESSED AREAS AND POSSIBLE CRACKING. CHROME-PLATED, NICKEL-PLATED, AND UNPLATED TOOLS MAY BE USED ON TITANIUM PARTS. NOTE HPC rotor stages 1 through 14 blades are made of titanium. a.

For initial removal of material, file or blend in longitudinal direction, parallel with airfoil length, using smooth file, not over 8.0 inches (203 mm) long, or emery cloth.

b.

Power tools may be used for initial heavy removal of material. NOTE All blend repair and polishing shall be done in direction parallel with blade leading or trailing edges. Do not use power tools for final polish or finish blending.

c.

Final blend and polish to depth of 0.020-0.030 in. (0.51-0.76 mm) shall be accomplished by hand.




d.

Using medium stone, blend any areas having been blended with file or emery cloth and areas containing small nicks and dents.

e.

Using fine emery cloth and/or fine abrasive stone, polish blended area until finish looks and feels like original.

f.

Blend any HPC rotor blade having trailing edge cross-section of less than 0.010 in. (0.25 mm) until it is at least 0.010 in. (0.25 mm).

g.

Blend HPC rotor blades leading and trailing edges (figure 2), per limits for stage of HPC rotor blade being repaired, as follows:

h.

(1)

Do not exceed maximum repairable limits for HPC rotor blade being repaired.

(2)

Minimum blend radius (Dim B) will be eight times the depth of blend (Dim A).

(3)

Blend HPC rotor blade leading edges to as near original configuration as possible.

(4)

Blend HPC rotor blade trailing edges to remove all sharp edges.

(5)

Contour blended edges.

Blend HPC rotor blade corners, per limits for stage of HPC rotor blade being repaired, as follows: (1)

Whenever possible, remove damage on leading and/or trailing edge corners by blending smooth radius.

(2)

Remove as little metal as possible.

(3)

Do not exceed limits for HPC rotor blade stage.

(4)

If both corners are damaged, blend out damage.

(5)

If only one corner is damaged, blend out damage at leading or trailing edge corner. CAUTION

DO NOT STRAIGHTEN BENT TIPS. i.

Blend HPC rotor blade squealer tips (figure 3), per limits for stage of HPC rotor blade being repaired, as follows: (1)

Accept HPC rotor blade tips bent less than 15 degrees if there are no cracks.



j.


(2)

Remove HPC rotor blade tips bent over 15 degrees by blending.

(3)

Blend nicks, gouges, dents, and cracks by removing damaged metal.

(4)

Cracks shall be completely removed by blending.

(5)

No cracks, burrs, or rolled metal are allowed and shall be completely removed by deburring/blending.

(6)

No heat discoloration allowed. Replace blade(s) per WP 215 00.

Inspect blended area by spot fluorescent-penetrant (FPI) method after blending. No cracks allowed.

Figure 2. HPC Rotor Blade Leading and Trailing Edge Blending




Figure 3. HPC Rotor Blade Tip Blending




High Pressure Compressor Rotor Blisk and Stage 1 Blade Repair. WARNING TITANIUM DUST IS A FIRE HAZARD. KEEP FLAMES AND SPARKS AWAY FROM WORK AREA. DISPOSE OF DUST IN APPROVED CONTAINERS. KEEP A SUITABLE COMPOUND AVAILABLE FOR EXTINGUISHING CLASS D FIRES. DO NOT USE WATER. IN AN EMERGENCY, DRY SAND CAN BE USED AS A FIRE FIGHTING AGENT. CAUTION TITANIUM PARTS SHALL NOT BE BLEND REPAIRED WITH TOOLS SUCH AS GRINDING WHEELS, FILES, STONES, OR EMERY CLOTHS THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DO NOT USE SILVER OR CADMIUM TOOLS ON TITANIUM PARTS. WHEN CADMIUM- OR SILVER-PLATED TOOLS ARE USED ON TITANIUM PARTS, PARTICLES OF CADMIUM OR SILVER MAY BECOME EMBEDDED IN TITANIUM. AT TEMPERATURES ABOVE 500°F (316°C), METALS CAN CAUSE EMBRITTLEMENT, RESULTING IN OVERSTRESSED AREAS AND POSSIBLE CRACKING. CHROME-PLATED, NICKEL-PLATED, AND UNPLATED TOOLS MAY BE USED ON TITANIUM PARTS. a.

Blend HPC rotor blisk and stage 1 blades (figure 4) as follows: (1)

Blend maximum of 20 percent of HPC rotor blisk and stage 1 blade airfoils to limits shown.

(2)

After blending, minimum trailing edge thickness of 0.010 in. (0.25 mm) is required. Minimum tip chord remaining shall be 2.439 in. (61.95 mm).

(3)

Blend limit of Dim W shall be 0.30 in. (7.6 mm) maximum.

(4)

Blend limit of Area D shall be 0.05 in. (1.2 mm) maximum.

(5)

Blend limit of Area B shall be 0.02 in. (0.5 mm) maximum.

(6)

After blending, spot FPI blended areas. No cracks are allowed.

(7)

If HPC rotor stage 1 blades limits are exceeded, replace HPC rotor stage 1 blades per WP 215 00.

(8)

If blisk limits are exceeded, replace gas generator per WP 301 00.




Figure 4. HPC Rotor Blisk and Stage 1 Blade Blending




High Pressure Compressor Stage 2 Blade Repair. WARNING TITANIUM DUST IS A FIRE HAZARD. KEEP FLAMES AND SPARKS AWAY FROM WORK AREA. DISPOSE OF DUST IN APPROVED CONTAINERS. KEEP A SUITABLE COMPOUND AVAILABLE FOR EXTINGUISHING CLASS D FIRES. DO NOT USE WATER. IN AN EMERGENCY, DRY SAND CAN BE USED AS A FIRE FIGHTING AGENT. CAUTION TITANIUM PARTS SHALL NOT BE BLEND REPAIRED WITH TOOLS SUCH AS GRINDING WHEELS, FILES, STONES, OR EMERY CLOTHS THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DO NOT USE SILVER OR CADMIUM TOOLS ON TITANIUM PARTS. WHEN CADMIUM- OR SILVER-PLATED TOOLS ARE USED ON TITANIUM PARTS, PARTICLES OF CADMIUM OR SILVER MAY BECOME EMBEDDED IN TITANIUM. AT TEMPERATURES ABOVE 500°F (316°C), METALS CAN CAUSE EMBRITTLEMENT, RESULTING IN OVERSTRESSED AREAS AND POSSIBLE CRACKING. CHROME-PLATED, NICKEL-PLATED, AND UNPLATED TOOLS MAY BE USED ON TITANIUM PARTS. a.

Blend HPC rotor stage 2 blades (figure 5) as follows: (1)

Blend maximum of 20 percent of HPC rotor stage 2 blade air foils to within limits. Blend leading edges, only if required to meet section contour.

(2)

After blending, minimum trailing edge thickness of 0.010 in. (0.25 mm) is required. Minimum tip chord remaining shall be 2.33 in. (59.2 mm).

(3)

Blend limits of Dim Y and Dim Z added together shall be 0.30 in. (7.6 mm) maximum.

(4)

Blend limit Dim X shall be 2.15 in. (54.6 mm) maximum.

(5)

Blend limit of Dim W shall be 0.30 in. (7.6 mm) maximum.

(6)

Blend limit of Area B shall be 0.02 in. (0.5 mm) maximum.

(7)

After blending, spot FPI blended area. No cracks allowed.

(8)

If limits are exceeded, replace HPC rotor stage 2 blades per WP 215 00.




Figure 5. HPC Rotor Stage 2 Blade Blending



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines 10. High Pressure Compressor Stages 3 through 16 Blade Repair. WARNING

TITANIUM DUST IS A FIRE HAZARD. KEEP FLAMES AND SPARKS AWAY FROM WORK AREA. DISPOSE OF DUST IN APPROVED CONTAINERS. KEEP A SUITABLE COMPOUND AVAILABLE FOR EXTINGUISHING CLASS D FIRES. DO NOT USE WATER. IN AN EMERGENCY, DRY SAND CAN BE USED AS A FIRE FIGHTING AGENT. CAUTION TITANIUM PARTS SHALL NOT BE BLEND REPAIRED WITH TOOLS SUCH AS GRINDING WHEELS, FILES, STONES, OR EMERY CLOTHS THAT HAVE BEEN USED TO REPAIR OTHER TYPES OF METAL. DO NOT USE SILVER OR CADMIUM TOOLS ON TITANIUM PARTS. WHEN CADMIUM- OR SILVER-PLATED TOOLS ARE USED ON TITANIUM PARTS, PARTICLES OF CADMIUM OR SILVER MAY BECOME EMBEDDED IN TITANIUM. AT TEMPERATURES ABOVE 500°F (316°C), METALS CAN CAUSE EMBRITTLEMENT, RESULTING IN OVERSTRESSED AREAS AND POSSIBLE CRACKING. CHROME-PLATED, NICKEL-PLATED, AND UNPLATED TOOLS MAY BE USED ON TITANIUM PARTS. a.

Blend HPC rotor stages 3 through 16 blades (figure 6) as follows: (1)

Blend maximum of 20 percent of HPC rotor blade airfoils in affected stage to within limits. Blend leading edges, only if required to meet section contour.

(2)

After blending, minimum trailing edge thickness of 0.010 in. (0.25 mm) is required.

(3)

If damage leaves tip section (Dim Y or Dim Z) of less than 0.156 in (3.96 mm), remove section.

(4)

Dim U shall be measured from line between fillet radii R1 and bottom of damaged area. Blend limit for Dim U shall be 0.03 in. (0.7 mm).

(5)

Minimum radius (R1) shall be 0.080 in.

(6)

Maximum corner radius (R2) shall be 1/10 of blade chord length.

(7)

Blend limits of Dim Y and Dim Z shall be added together to find Dim YZ. Maximum Dim YZ shall be per table 2.

(8)

Dim F shall be per table 2.

(9)

Blend limit for Area B shall be 0.020 in. (0.5 mm) maximum.




(10) Blend limit for Dim W shall be 0.30 in. (7.6 mm) maximum. (11) If limits are exceeded, replace HPC rotor blade per WP 215 00. Table 2. Stages 3 through 16 Blade Limits Stage 3 4 5 6 7 8 9 10 11 12 13 14 15 16

2.00 in. 0.75 in. 0.50 in. 0.25 in. 1.0 in. 1.0 in. 0.75 in. 0.75 in. 0.75 in. 0.50 in. 0.50 in. 0.25 in. 0.25 in. 0.25 in.

Dim F (50.8 mm) (19.0 mm) (12.7 mm) (6.3 mm) (25.4 mm) (25.4 mm) (19.0 mm) (19.0 mm) (19.0 mm) (12.7 mm) (12.7 mm) (6.3 mm) (6.3 mm) (6.3 mm)

0.30 in. 0.30 in. 0.28 in. 0.28 in. 0.24 in. 0.24 in. 0.22 in. 0.22 in. 0.20 in. 0.20 in. 0.20 in. 0.20 in. 0.20 in. 0.20 in.

Dim YZ (7.6 mm) (7.6 mm) (7.1 mm) (7.1 mm) (6.0 mm) (6.0 mm) (5.5 mm) (5.5 mm) (5.0 mm) (5.0 mm) (5.0 mm) (5.0 mm) (5.0 mm) (5.0 mm)

Figure 6. HPC Rotor Stages 3 through 16 Blade Blending 16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES SINGLE ANNULAR COMBUSTOR INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Single Annular Combustor Inspection. ..............................................................................

3


GEK 105054 Volume II WP 425 00 1.


Introduction. This work package provides instructions for inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, single annular combustor.

2.


Number

Operation and Maintenance Manual, Volume II Single Annular Combustor Replacement High Pressure Turbine Stage 1 Nozzle Inspection High Pressure Turbine Stage 2 Nozzle Inspection

GEK 105054 WP 203 00 WP 427 00 WP 428 00

3.


4.


5.





Single Annular Combustor Inspection. a.

Inspect single annular combustor per table 1 and figure 1. Table 1. Single Annular Combustor Inspection

Inspect




1. All Surfaces for: a.

Discoloration

Serviceable

_

_

b.

Carbon accumulation

Any amount

_

_

2. Riveted Joints for: a.

Loose, cracked, or missing rivets

Six nonadjacent rivets in each rivet circle may be loose, cracked, or missing

Not repairable

Replace combustor per WP 203 00

b.

Cracked or torn rivet holes in cowl and skirts

One crack 0.030 in. (0.76 mm) long per hole; 20 holes max per rivet circle

Not repairable


3. Dome Band and Dome Plate (Excluding Overhung Surfaces) for: a.

Axial cracks

Any number, less than 1.25 in. (31.7 mm) long; one crack greater than 1.25 in. (31.7 mm) in each swirl cup location, max length of 2.25 in. (57.1 mm) not to exceed eight per dome

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Single Annular Combustor Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect



3. Dome Band and Dome Plate (Excluding Overhung Surfaces) for: - (cont.) b.


Any number, less than 0.75 in. (19.0 mm) long, five cracks 2.25 in. (57.1 mm) long separated by 1.00 in. (25.4 mm) from any other crack greater than 0.75 in. (19.0 mm) long

Not repairable


4. Trumpet and Swirl Cup (Excluding Overhung Surfaces) for: a.

Cracks

Four cracks, 1.25 in. (31.7 mm) long per item; any number less than 0.50 in. (12.7 mm) long

Not repairable


b.

Distortion of trumpet

Any amount

_

_

5. Dome Assembly (Dome Band, Dome-Plate, Trumpet, and Swirl Cup) for: a.

Burn through or missing metal of nonoverhung surfaces

Any amount less than 90 degrees maximum burn through of domeplate around any one swirl cup. Burn through limited to eight areas per dome, maximum size 1.0 in. (25.4 mm) by 1.0 in. (25.4 mm). Any amount of trumpet distress is allowed

Not repairable





Inspect



5. Dome Assembly (Dome Band, Dome-Plate, Trumpet, and Swirl Cup) for: - (cont.) NOTE Burn through in combustor dome will reduce the cooling flow to the high pressure turbine (HPT) nozzles vanes. Inspect HPT stage 1 and 2 nozzle vanes per WP 427 00 and WP 428 00. b.

Burn through or missing metal of overhung surfaces

Any amount

_

_

6. Igniter sleeve for: a.

Cracks


Not repairable


b.

Burns

0. 13 in. (3.3 mm) burn permissible on bottom of ferrule (flame side)

Not repairable


c.

Wear

0.75 in. (19.0 mm) inside diameter (ID) max

Not repairable


Not repairable


7. Inner and Outer Liners for: a.


Any number, noninterconnecting cracks per band, each 1.00 in. (25.4 mm) long separated by 2.00 in. (50.8 mm) from any other crack. Total length of all circumferential cracks in any band shall not exceed 7.00 in. (177.8 mm)




Inspect



7. Inner and Outer Liners for: - (cont.) b.

Axial cracks

Six cracks per liner, max length not to exceed 2 adjoining bands (3 rows of cooling holes), any number of cracks 1.25 in. (31.7 mm) per band. Axial and circumferential cracks, 1.00 in. (25.4 mm) or longer shall have minimum separation of 2.00 in. (50.8 mm)

Not repairable


c.

Burns

Six burned through areas of 0.75 in. (19.0 mm) by 1.00 in. (25.4 mm) per liner separated by 2.50 in. (63.5 mm)

Not repairable


d.

Distortion

Any amount, within 0.50 in. (12.7 mm) from original contour

Not repairable


8. Cowl for: a.

Burns at fuel nozzle eyelet (fuel nozzle removed)

Accept three burn through areas of 0.25 in. (6.3 mm) by 1.00 in. (25.4 mm)

Not repairable


b.

Cracks


Not repairable





Figure 1. Single Annular Combustor 7/(8 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE TURBINE ROTOR INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Turbine Rotor Inspection. ..........................................................................

3


GEK 105054 Volume II WP 426 00 1.


Introduction. This work package provides instructions for inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, high pressure turbine (HPT) rotor.

2.


Number

Operation and Maintenance Manual, Volume II High Pressure Turbine Rotor Replacement High Pressure Turbine Stage 2 Nozzle Assembly Replacement High Pressure Turbine Rotor Blade Replacement

GEK 105054 WP 201 00

3.


4.


5.


SWP 201 01 WP 202 00




High Pressure Turbine Rotor Inspection. a.


b.

Remove HPT stage 2 nozzle per SWP 201 01.

c.

Inspect HPT rotor per tables 1 and 2 and figures 1 through 7. Table 1. HPT Rotor On-Site Maximum Serviceable Limits

Inspect



FORWARD SHAFT ROTATING AIR SEALS 1. All Areas (except serrations) for: a.

Cracks

Not serviceable

Not repairable

Replace HPT rotor per WP 201 00

b.


Any number, 0.015 in. (0.38 mm) deep after removal of high metal

Not repairable


Not serviceable

Any amount

Remove high metal

2. Seal Serrations for: a.

Turned metal

NOTE

•

Maximum individual or cumulative length of blends on any one tooth of seal shall not exceed 5.0 in. (127 mm).

• Total cumulative length of all blends on six serrations per rotating

air seal shall not exceed 16 in. (406.4 mm), or forward tooth on forward rotating air seal may be removed 100 percent if cumulative length of all blends on remaining seal teeth do not exceed 8 in. (203.2 mm).

b.

•

Measurements to be made at outside diameter of serrations (including blend radius).

•

Do not leave serration sections less than 1.0 in. (25.4 mm) long between blends.

Cracked or cracked out serrations

Not serviceable

Any number may be blended out if completely removed between limits of preceding NOTE and figure 2

Blend and inspect for cracks



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Rotor - (Cont.) On-Site Maximum Serviceable Limits

Inspect



2. Seal Serrations for: - (cont.) c.

Nicks and dents




d.

Scratches




e.

Bending

Not serviceable

Any length may be straightened max of 0.13 in. (3.3 mm) axially

Straighten with hand tools. Serration shall not be overbent and rebent. Inspect for cracks

FORWARD SHAFT NOTE Limits are for areas aft of 13 in. (330.2 mm) from forward shaft front face. 1. All Areas for: a.

Cracks

Not serviceable

Not repairable





Inspect



2. Splines for: a.

High metal

Not serviceable

Any amount

Remove high metal

b.

Nicks and dents

Any number, 0.03 in. (0.76 mm) wide by 0.25 in. (6.3 mm) long, after removal of high metal. None allowed in root radii. Total area of nicks and dents on each tooth not to exceed 15 percent of that tooth area

Not repairable


c.

Scratches

Any number, 0.020 in. (0.50 mm) deep, 0.06 in. (1.5 mm) wide, 0.63 in. (16.0 mm) long, after removal of high metal. None allowed in root radii. Total area of scratches on each tooth not to exceed 10 percent of that tooth area

Not repairable


3. Pilot for: a.

Nicks and dents


Not repairable


b.

Pick up and high metal

Not serviceable

Any amount

Remove high metal

c.

Scratches

Any number, any length, 0.010 in. (0.25 mm) deep, any length

Any number if not more than 13 percent of surface is affected

Blend to remove damage




Inspect



4. External Surfaces for: a.

Nicks


Any number, 0.016 in. (0.40 mm)


b.

Dents


Not repairable


c.

Scratches




Not serviceable

Any number that can be removed by blending to max of 0.031 in. (0.78 mm) deep. Holes can be increased in diameter by 0.125 in. (3.17 mm) and edge radius increased to 0.125 in. (3.17 mm) max (true radius not required) to remove damage


5. Cooling Air Holes for: a.

Nicks and scratches




Inspect



STAGES 1 AND 2 BLADE RETAINERS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace blade retainer per WP 202 00. However, engine vibration levels may not be exceeded during engine operation

b.

Nicks and dents




c.

Scratches




Not repairable


STAGES 1 AND 2 DISKS 1. All Areas for: a.

Cracks

Not serviceable

2. Dovetail Serrations for: a.

Nicks and dents

Three dovetail serrations, 0.010 in. (0.25 mm) deep, after removal of high metal

Corner radii of dovetail and posts can be locally increased to 0.078 in. (1.98 mm) radius to remove nicks and dents


b.

Scratches

Any number, any length, 0.003 in. (0.07 mm) deep, after removal of high metal, if located on root radii or pressure faces. Root radii or pressure face scratches are not serviceable

Not repairable


c.

Fretting

Not serviceable

Not repairable

Replace HPT rotor per WP 201 00 7



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

Inspect




3. Rim (OD of disks) for: a.

Nicks


Any number that can be removed by blending to max depth of 0.047 in. (1.19 mm)


b.

Dents


Not repairable


c.

Scratches


Any number that can be removed by blending to max depth of 0.047 in. (1.19 mm) and 0.25 in. (6.3 mm) long


d.

Galling

Any number, 0.010 in. (0.25 mm) deep, 0.50 in. (12.7 mm) long, after removal of high metal and sharp edges

Not repairable


4. Disk Web (Stage 2 Disk Only) for: a.

Nicks and scratches

Any number, any length 0.016 in. (0.40 mm) deep, after removal of high metal

Any number that can be removed by blending to max depth of 0.031 in. (0.78 mm) and 0.50 in. (12.7 mm) long. Polish to same finish as adjacent area


b.

Dents


Not repairable





Inspect



STAGES 1 AND 2 DAMPERS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace damper

b.

Galling


Not repairable

Replace damper

STAGES 1 AND 2 SEALS 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace seal

b.

Galling


Not repairable

Replace seal


Not repairable

Replace seal

2. End Faces for: a.


THERMAL SHIELD 1. All Areas Except Seal Serrations for: a.

Cracks

Not serviceable

Not repairable


b.

Scratches

Any number, any length, 0.005 in. (0.12 mm) deep, 0.50 in. (12.7 mm) long



c.

Nicks



Remove high metal

d.

Dents


Not repairable





Inspect



2. External Seal Serrations for: a.

Turned metal

Not serviceable

Any amount

Remove high metal

NOTE

•

Maximum cumulative blend length of any one tooth shall not exceed 5 in. (127 mm).

•

Total cumulative length of all blends on three serrations shall not exceed 10 in. (254 mm).

•

Measurements to be made at OD of serrations (including blend radius).

•

Do not leave sections of seal tooth shorter than 1.0 in. (25.4 mm) long between blends.

b.


Not serviceable

Any number may be blended out if completely removed within limits of preceding NOTE and Blend min OD limits of figure 2


c.

Nicks

Any number, 0.031 in. (0.78 mm) deep, if there is no crack and high metal is removed

Any number may be blended out if completely removed within limits of preceding NOTE and figure 2


d.

Dents


Any number may be blended out if completely removed within limits of preceding NOTE and figure 2


e.

Bending

Not serviceable

Any number may be straightened at max 0.125 in. (3.17 mm) axially

Straighten; may not be overbent and rebent. Inspect straightened area for cracks




Inspect



AFT SHAFT 1. All Areas Except Seal Serrations for: a.

Cracks

Not serviceable

Not repairable


Accept nicks and dents 0.063 in. (1.60 mm) deep, after removal of high metal

Total removal of half of entrance thread is permissible if remainder of threads are free of damage. If entrance thread is free of damage, cumulative length of damage in other areas shall not exceed 50 percent of one complete thread

Remove all threads, pickup, and high metal

2. Threads for: a.

Damage (nicks, dents, pickup, or high metal)

3. No. 5 Bearing Journal for: a.

Pickup or high metal

Not serviceable

Any amount

Remove high metal

b.

Nicks, dents, scores, and scratches

Any number, 0.010 in. (0.25 mm) deep, after removal of high metal, if not more than 5 percent of journal OD affected in any 90 degree sector

Not repairable





Inspect



4. No. 5 Bearing Air and Oil Seal Serrations for: NOTE

• Total cumulative length of all blends on aft shaft forward rotating air seal serrations shall not exceed 7 in. (177.8 mm).

•

Total cumulative length of all blends on aft shaft aft rotating air seal serrations and air/oil seal serrations shall not exceed 3 in. (76.2 mm).

•

Measurements to be made at OD of serrations (including blend radius).

• Minimum blend radius to be 0.063 in. (1.60 mm). Do not leave serration sections less than 0.50 in. (12.7 mm) long between blends.

a.


Not serviceable

Any number may be blended out if completely removed by blending max of 0.100 in. (2.5 mm) deep, 1.0 in. (25.4 mm) long and within limits of preceding NOTE and figure 2


b.

Nicks and dents

Any number, 0.031 in. (0.78 mm) deep, if there is no crack and high metal is removed

Any number may be blended out if completely removed by blending max of 0.100 in. (2.5 mm) deep, 1.0 in. (25.4 mm) long, and within limits of preceding NOTE and figure 2


c.

Bending

Not serviceable

Any number may be straightened at max 0.063 in. (1.60 mm) axially

Straighten with hand tools. Serration shall not be overbent and rebent. Inspect straightened area for cracks



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

Inspect




5. Flanges for: a.

Nicks


Any number that can be removed by blending max of 0.031 in. (0.78 mm) deep


b.

Dents


Not repairable


c.

Scratches




d.

High metal

Not serviceable

Any amount

Remove high metal

e.

Damaged wrenching slots

0.031 in. (0.78 mm) deformation, after removal of high metal

Not repairable


6. All Other Areas for: a.

Nicks




b.

Dents


Not repairable


c.

Scratches







Inspect



HPT ROTOR DAMPER SLEEVE 1. All Areas for: a.

Nicks and scratches

Not serviceable

Any amount to 0.050 in. (1.27 mm) deep

Remove high metal

b.

Buckling

Not serviceable

Not repairable

Replace HPT rotor damper sleeve*

c.

Cracks

Not serviceable

Not repairable

Replace HPT rotor damper sleeve*

Any amount to 0.030 in. (0.76 mm) deep. No fretting permitted in fillet at aft area J

Any amount to 0.006 in. (0.15 mm) deep

Remove high metal

2. Area J for: a.

Fretting

PRESSURE TUBE 1. Internal Surfaces for: a.

Cracks

Not serviceable

Not repairable


b.

Buckling

Not serviceable

Not repairable


COUPLING NUT 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace coupling nut

b.

Pickup or high metal

Not serviceable

Not repairable

Replace coupling nut




Inspect



2. Threads for: a.

Damage

Not serviceable

All thread pickup and high metal shall be removed. Total removal of entrance thread is permissible if remainder of threads are free of damage; cumulative length of other thread damage shall not exceed 1/2 of one complete thread

Remove damage with fine file or honing stone. Be careful not to unnecessarily remove protective finish. If entrance thread is removed, lead-in radii shall be contoured same as original

b.

Missing silver plating

Five percent missing

Not repairable

Replace part

c.


Not serviceable

Any amount


Not serviceable

Any amount


3. Contact Face for: a.


4. Splines for: a.

Nicks and dents

Any amount, 0.010 in. (0.25 mm) deep by 0.030 in. (0.76 mm) wide by 0.125 in. (3.17 mm) long

0.030 in. (0.76 mm) deep by 0.063 in. (1.60 mm) wide by 0.50 in. (12.70 mm) long over 85 percent of all tooth surfaces *May be repairable. Consult GE for disposition of replaced parts.

Remove high metal and blend sharp edges




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



Figure 2. Blend Repair of Seal Serrations

Figure 3. HPT Rotor Damper Sleeve 17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 4. HPT Pressure Tube Table 2. HPT Rotor Blade Inspection On-Site Maximum Serviceable Limits

Inspect



STAGE 1 BLADES 1. Leading Edge for: a.

Axial and radial cracks in area A only

Any number, not extending beyond leading edge or connect to adjacent nose holes

Not repairable

Replace blade per WP 202 00

b.

Cracks not intersecting cooling holes in area B

Not serviceable

Not repairable


c.

Radial cracks out of leading edge holes in area B

Any number, if not connecting 2 holes and do not turn into axial direction

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.)

Inspect




1. Leading Edge for: - (cont.) d.

Axial cracks out of leading edge holes in area B

Not serviceable

Not repairable


e.

Nicks and scratches in area A

Any number, 0.015 in. (0.38 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart, if there is no torn metal or nicks do not extend into or block nose or gill holes

Not repairable


f.

Nicks and scratches in area B

Three nicks or scratches 0.008 in. (0.20 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal or surface distortion except that surface distortion is allowed in nick or scratch itself

Not repairable


g.

Dents in area A

Any number, if damage does not cause torn metal or cracks beyond gill holes

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect



1. Leading Edge for: - (cont.) h.

Dents in area B

Three dents, 0.010 in. (0.25 mm) deep or out of contour 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal, or surface distortion, except that surface distortion is allowed in dent itself

Not repairable


i.

Tears

Not serviceable

Not repairable


j.

Blocked leading edge holes

Total of three holes, one only in area B, separated by one open hole

Not repairable


k.

Missing metal in area A or B

Not serviceable

Not repairable


l.

Missing coating

No parent material exposed

Not repairable


2. Trailing Edge for: a.

Cracks

Not serviceable

Not repairable


b.

Blocked air holes

Three holes in any area above seventh hole, if not adjacent to each other. None allowed in bottom seven holes

Not repairable


c.

Oxidation/ erosion

Degradation of edge thickness to 0.05 in. (1.2 mm), if trailing edge hole wall each side is no less than 0.015 in. (0.38 mm)

Not repairable





Inspect



2. Trailing Edge for: - (cont.) d.


Any number, 0.015 in. (0.38 mm) deep, 0.100 in. (2.54 mm) long, and 0.125 in. (3.17 mm) apart

Not repairable


e.


Three nicks or scratches 0.008 in. (0.20 mm) deep, 0.100 in. (2.54 mm) long and 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal, or surface distortion, except that surface distortion is allowed in nick or scratch itself

Not repairable


f.

Dents in area A

Six allowed, 0.010 in. (0.25 mm) deep or out of contour

Not repairable


g.

Dents in area B

Three dents, 0.008 in. (0.20 mm) deep or out of contour, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal, or surface distortion except that surface distortion is allowed in dent itself

Not repairable


h.

Tears

Not serviceable

Not repairable





Inspect




Cracks in intersecting cooling holes

Not serviceable

Not repairable


b.

Axial cracks out of gill holes

Not serviceable

Not repairable


c.

Blocked gill holes (1)

Concave side gill holes

Two holes if not adjacent to each other

Not repairable


(2)

Convex side gill holes

Three holes only. One within first seven holes from root. Each plugged hole must be separated from next plugged hole by two open holes, except above tenth hole from root where two adjacent holes may be plugged, if third plugged hole (if there is one) is three or more holes from plugged adjacent holes

Not repairable





Inspect



3. Concave and Convex Surfaces for: - (cont.) d.


Any number, 0.015 in. (0.38 mm) deep and no restrictions on length or spacing; any number, 0.25 in. (6.3 mm) deep, 0.100 in. (2.5 mm) long and 0.250 in. (6.35 mm) apart

Not repairable


e.


Any number, 0.015 in. (0.38 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart

Not repairable


f.

Dents in area A

Any number, 0.030 in. (0.76 mm) deep, 0.100 in. (2.54 mm) diameter

Not repairable


g.

Dents in area B not allowed in fillet radius at leading and trailing edges

Any number, 0.015 in. (0.38 mm) deep separated from any other dents by 0.100 in. (2.54 mm)

Not repairable


4. Tip Area for: a.

Nicks and scratches

Any number





Inspect



4. Tip Area for: - (cont.) b.

Radial cracks in parent metal

Three radial cracks, 0.200 in. (5.08 mm) long each extending inward from top of blade. Any number that extend from top of blade to top of tip cap retention lug. If cracks extend into tip cap, use limits for cracks in tip cap

Not repairable


c.

Axial cracks in parent metal

One per side, 0.400 in. (10.16 mm) long, if damage is above tip cap retention lug

Not repairable


d.

Dent or curled

Any amount, if damage is above tip cap retention lug and no cracked parent metal is visible below tip cap lug

Not repairable


e.

Wear due to shroud rub

Wear may not extend to within 0.070 in. (1.77 mm) of tip cap retention lug

Not repairable


f.

Missing metal

Any amount above tip cap retention lug

Not repairable





Inspect



4. Tip Area for: - (cont.) g.

Missing coating

Any amount

_

_

5. Tip Cap for: a.

Blocked air holes

One hole per cap can be plugged

Not repairable


b.

Braze area or cracks in length of braze

Any number, if cumulative length does not exceed 0.200 in. (5.08 mm) and braze seal is maintained

Not repairable


c.

Cracks

One allowed in cap in each flat 0.100 in. (2.54 mm) long. Any cap crack connecting two or more cooling holes is not allowed. Any crack accompanied by cap bowing is not allowed

Not repairable


6. Top Surface and Edges of Blades Platform (not including root radius) for: a.

Nicks and scratches


Not repairable


b.

Dents


Not repairable


c.

Cracks ( forward and aft edges only)

Any number, any length, if no cracks extend completely through plat form thickness or into root radius of airfoil

Not repairable





Inspect



7. Airfoil for: a.

Metal splatter

Any amount, if thickness does not exceed 0.005 in. (0.12 mm). Chipping or flaking is acceptable

Not repairable


b.

Distortion or evidence of burning or melting

Not serviceable

Not repairable


8. Forward Seal Lip for: a.

Circumferential wear groove on OD and ID of forward seal lip

Groove may be 0.02 in. (0.50 mm) deep, 0.150 in. (3.81 mm) wide, if groove is within 0.150 in. (3.81 mm) from for ward edge of seal lip

Not repairable


b.

Circumferential wear groove on OD of aft seal

Groove may be 0.02 in. (0.50 mm) deep, 0.150 in. (3.81 mm) wide, if groove is within 0.150 in. (3.81 mm) from aft edge of seal lip

Not repairable


STAGE 2 BLADES ONLY 1. Leading and Trailing Edges for: a.

Cracks

Not serviceable

Not repairable


b.


Any number

Not repairable





Inspect



1. Leading and Trailing Edges for: - (cont.) c.

Nicks and scratches in area B (including root radius)

Three nicks or scratches 0.008 in. (0.20 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal or surface distortion, except that surface distortion is allowed in nick or scratches itself

Not repairable


d.

Dents in area A

Any number, 0.010 in. (0.25 mm) deep or out of contour, 0.050 in. (1.27 mm) apart

Not repairable


e.

Dents in area B (including root radius)

Any number, 0.008 in. (0.20 mm) deep or out of contour, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal or surface distortion except that surface distortion is allowed in dent itself

Not repairable


f.

Tears

Not serviceable

Not repairable


g.

Missing coating

No parent material exposed

Not repairable





Inspect




Cracks

Not serviceable

Not repairable


b.


Any number, 0.008 in. (0.20 mm) deep and no restrictions on length or spacing, or any number 0.020 in. (0.50 mm) deep, 0.060 in. (1.52 mm) long, and 0.250 in. (6.35 mm) apart

Not repairable


c.

Nicks and scratches in area B (including root radius)

Three nicks or scratches 0.008 in. (0.20 mm) deep, 0.100 in. (2.54 mm) long, 0.125 in. (3.17 mm) apart if there is no torn metal, raised metal or surface distortion, except that surface distortion is allowed in nick or scratch itself

Not repairable


d.

Dents in area A

Any number, 0.030 in. (0.76 mm) deep, 0.060 in. (1.52 mm) diameter

Not repairable





Inspect



2. Concave and Convex Surfaces for: - (cont.) e.

Dents in area B (including root radius)

Any number, 0.008 in. (0.20 mm) deep or out of contour, 0.125 in. (3.17 mm) apart, if there is no torn metal, raised metal or surface distortion except that surface distortion is allowed in dent itself

Not repairable


3. Tip Area for: a.

Nicks and scratches

Any number

_


b.

Radial cracks in parent metal

Three radial cracks 0.200 in. (5.08 mm) long each extending inward from top of blade. Any number that extend from top of blade to top of tip cap lip. If cracks extend into tip cap, use limits for cracks in tip cap

Not repairable


c.

Axial cracks in parent metal

One per side, 0.400 in. (10.16 mm) long, if damage is above tip cap lip

Not repairable


d.

Bent or curled

Any amount, if damage is above tip cap lip and no cracked parent metal is visible below tip cap lip

Not repairable





Inspect



3. Tip Area for: - (cont.) e.

Wear due to shroud rub

Wear may not extend to within 0.070 in. (1.77 mm) of tip cap lip

Not repairable


f.

Missing metal

Any amount above tip cap lip

Not repairable


g.

Missing coating

Any amount

_

_

4. Tip Cap for: a.

Blocked air holes

No holes may be plugged

Not repairable


b.

Braze area or cracks in length of braze

No cracks allowed

Not repairable


c.

Cracks in tip cap

Any number which do not extend more than 0.010 in. (0.25 mm) across tip cap flat. Cracks accompanied by cap bowing not allowed

Not repairable


5. Top Surface and Edges of Platform (not including root radius) for: a.

Cracks on side of platform or forward and aft edges

Any number, any length, if no cracks extend into root radius of airfoil

Not repairable


b.

Nicks and scratches


Not repairable


c.

Dents


Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Rotor Blade Inspection - (Cont.)

Inspect




6. Blade Shank for: a.

Nicks and scratches


Not repairable


b.

Dents

Three per surface 0.030 in. (0.76 mm) deep

Not repairable


c.

Cracks

Not serviceable

Not repairable


d.

Indications of cracks in shank between dovetail and damper boss areas

Not serviceable

Not repairable


7. Dovetail Serrations for: a.

High Metal

Not serviceable

Not repairable


b.

Nicks, dents, and scratches in areas D and E

Not serviceable

Six per serration 0.060 in. (1.52 mm) in diameter, 0.005 in. (0.12 mm) deep, separated by 0.125 in. (3.17 mm), after removal of high metal

Hand stone

c.

Nicks, dents, and scratches in pressure face and area F

Not serviceable

Not repairable


8. Damper Boss Area for: a.

Cracks

Not serviceable

Not repairable


b.

Fretting or galling

0.005 in. (0.12 mm) deep

Not repairable





Inspect



9. Aft Seal Lips for: a.

Cracks

b.

Circumferential wear groove on OD of aft seal lip

Not serviceable

Not repairable

Groove may be Not repairable 0.020 in. (0.50 mm) deep, 0.150 in. (3.81 mm) wide, if groove is within 0.150 in. (3.81 mm) from aft edge of seal lip *May be repairable. Consult GE for disposition of replaced part.

Replace blade per WP 202 00 Replace blade per WP 202 00




Figure 5. HPT Stage 1 Rotor Blade 33 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 6. HPT Stage 2 Rotor Blade 34 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 7. Dovetail Serrations




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE TURBINE STAGE 1 NOZZLE INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Page

High Pressure Turbine Stage 1 Nozzle Disassembly. ....................................................... 20 High Pressure Turbine Stage 1 Nozzle Inspection............................................................ 3 High Pressure Turbine Stage 1 Nozzle Open Area (A4) Inspection. ................................ 24 High Pressure Turbine Stage 1 Nozzle Reassembly. ........................................................ 21


GEK 105054 Volume II WP 427 00 1.


Introduction. This work package provides instructions for the inspection and repair of LM2500+ Models GK and GV gas generators and Models PK and PV gas turbine high pressure turbine (HPT) stage 1 nozzle assembly.

2.

3.

4.

5.


Number

Operation and Maintenance Manual, Volume I Preventive Maintenance

GEK 105054 Chapter 11


Part No.

Gage, High Pressure Turbine Nozzle Open Area

2C6505



Thread Lubricant

GE Spec A50TF201





High Pressure Turbine Stage 1 Nozzle Inspection. a.

Inspect HPT stage 1 nozzle per table 1 and figures 1 and 2. Table 1. HPT Stage 1 Nozzle Inspection On-Site Maximum Serviceable Limits

Inspect



COMPRESSOR REAR FRAME (CRF) SEAL SUPPORT 1. Cone body for: a.

Cracks

Not serviceable

Not repairable

Replace part*

b.

Dents

Three dents, 0.30 (7.6 mm) in. diameter, 0.06 in. (1.5 mm) deep. Do not remove high metal

Not repairable

Replace part*

c.

Nicks and scratches


Not repairable

Replace part*

2. Mounting Flange for: a.

Cracks

Not serviceable

Not repairable

Replace part*

b.


Any number, 0.010 in. (0.25 mm) deep, after removal of high metal if not across full radial surface of flange

Not repairable

Replace part*

Six radial cracks, any length, minimum separation of 2.00 in. (50.8 mm). Circumferential cracks not serviceable

Not repairable

Replace part*

3. Stiffener for: a.

Cracks



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect



3. Stiffener for: - (cont.) b.

Dents

Three dents, 0.50 in. (12.7 mm) diameter, 0.06 in. (1.5 mm) deep. Do not remove high metal

Any amount

Mechanically straighten. Inspect for cracks

4. Self-Locking Nut Gang Channel for: a.

Improperly positioned or missing nuts

Not serviceable

Any number

Reposition or replace nut*

b.

Bent channel legs

Not serviceable

Any amount that will not produce cracking or improper nut containment

Straighten. Inspect for cracks

c.

Loss of running torque on nuts

Not serviceable

Not repairable

Replace part*

Any amount

Replace pin*

Not repairable

Replace cover*

5. Locating Pin (located on Rear Flange) for: a.

Loose or missing pins

Not serviceable

CRF SEAL SUPPORT BOLT COVER 1. All Areas of Cover for: a.

Cracks

Not serviceable

INNER AND OUTER HPT STAGE 1 NOZZLE SEALS 1. Seal Ring and Lugs for: a.

Cracks

Not serviceable

b.

Warpage

Not serviceable

Any amount

Mechanically straighten; no cracks allowed after rework

c.

Burned or missing lugs


Not repairable

Replace part*




Inspect



2. Rivets for: a.

Looseness

Not serviceable

Not repairable

Replace rivet*

b.

Tack weld broken

Not serviceable

Not repairable

Replace part*


Not repairable

Replace part*

3. Seal Lips for: a.

Wear or galling

BAFFLE LINER 1. All Seal Areas for: a.

Cracks

Not serviceable

Not repairable

Replace part*

b.

Bent or distorted

Any amount, if proper assembly can be accomplished and required minimum clearance can be maintained

Any amount

Mechanically straighten until part will assemble and minimum clearance requirements can be maintained. Inspect for cracks

c.

Bolts-air baffle to nozzle support for tightness

No loose bolts allowed

Any number

Tighten to specified torque

2. Support for: a.

Cracks

Any number, radial 0.25 in. (6.3 mm) hole

Not repairable

Replace part*

b.

Bends and/or distortion

Any amount, if proper assembly can be accomplished and required clearances maintained

_

Mechanically straighten until part will assemble and minimum clearances can be maintained. Inspect for cracks




Inspect



NOTE

• The nozzle vane segment limits have been defined assuming that a

hot section overhaul will be performed in an additional 15,000 or less hours of operation and that the engine will be borescoped per the semi-annual inspection requirements in Volume 1, Chapter 11.

•

A maximum of six HPT stage 1 nozzle segments may be replaced without remeasuring the HPT stage 1 nozzle assembly open area (A4).

HPT STAGE 1 NOZZLE SEGMENT 1. Vane Airfoil for: a.

Cracks propagating from nose holes toward other nose holes, including those interconnecting holes

Any number, any length, maximum width of 0.005 in. (0.12 mm), and three cracks maximum width of 0.010 in. (0.25 mm) are acceptable

Not repairable

Replace entire HPT stage 1 nozzle or maximum of six nozzle segments

NOTE To assist in visually gauging observed defects by comparison, the center-to-center dimension between nose or gill holes in any given row (radial direction) is approximately 0.094 in. (2.38 mm). b.

Cracks propagating aft from last row of nose holes on concave or convex side per airfoil

Any number, 0.005 in. (0.12 mm) wide and 0.150 in. (3.81 mm) long. One crack, 0.010 in. (0.25 mm) wide, between nose and gill holes on one side if same crack does not continue on other side. See Note

Not repairable





Inspect



1. Vane Airfoil for: - (cont.) NOTE Cracks from nose holes toward gill holes shall be more than 0.15 in. (3.8 mm) from cracks between flange cooling hole and gill hole. c.

Cracks propagating from concave and convex gill holes

Any number, 0.080 in. (2.03 mm) long One crack per side connecting up to three gill holes allowed. One crack permitted to connect with forward inner or outer flange cooling hole

Not repairable


d.

Axial cracks in concave surface

Three cracks not to exceed cumulative length of 1.00 in. (25.4 mm) per airfoil

Not repairable


e.

Radial cracks in concave surface

One crack, 0.50 in. (12.7 mm) long per airfoil, if it does not intersect with an axial crack. No radial cracks allowed within 0.50 in. (12.7 mm) from trailing edge

Not repairable





Inspect



1. Vane Airfoil for: - (cont.) f.

Cracks in concave side originating in trailing edge cooling slots and ribs

Any number of cracks, 0.120 in. (3.04 mm) long, extending from trailing edge slots. Each slot rib may have one crack extend across full width of rib, but not through vane

Not repairable


g.

Cracks on convex surface (not emanating from trailing edge)

Three cracks not to exceed cumulative length of 0.50 in. (12.7 mm). No radial cracks allowed in an area 1.20-1.40 in. (30.435.5 mm) from trailing edge, except cracks in airfoil to platform radius are acceptable

Not repairable


h.

Cracks from trailing edge forward (convex surface)

Any number, 0.120 in. (3.04 mm) long. Two per vane up to 0.35 in. (8.8 mm) long

Not repairable





Inspect



1. Vane Airfoil for: - (cont.) i.

Burns in trailing edge (loss of metal)

One area per vane, 0.75 in. (19.0 mm) long radially, 0.375 in. (9.52 mm) long axially

Not repairable


j.

Burns on concave or convex side

One area per vane, 0.75 in. (19.0 mm) long radially, 0.375 in. (9.52 mm) long axially

Not repairable


k.

Burns or erosion on vane leading edge

One area per vane, 0.625 in. (15.8 mm) wide, 0.75 in. (19.0 mm) long radially. No burn through allowed

Not repairable


l.

Nicks, scores, scratches, dents, or pits

Any number, any length, 0.010 in. (0.25 mm) deep. Three per airfoil, 0.020 in. (0.50 mm) deep, 0.10 in. (2.5 mm) long. Two nicks or dents, 0.05 in. (1.2 mm) deep within 0.75 in. (19.0 mm) of trailing edge

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.)

Inspect




1. Vane Airfoil for: - (cont.) NOTE The trailing edge slots shall be able to accept a 0.020 in. (0.50 mm) diameter pin. All sharp gouges at trailing edge should be removed by blending. m.

Tears, gouges, and nicks (loss of metal) on airfoil trailing edge (aft 0.40 in. (10.1 mm) of vane airfoil)

Three per airfoil, 0.06 in. (1.5 mm) long axially and 0.12 in. (3.0 mm) long radially. One per airfoil, 0.20 in. (5.0 mm) long axially and 0.30 in. (7.6 mm) long radially, after removal of high metal

Not repairable


n.

Bulging, bowing, or creases

Trailing edge bowing on aft 0.40 in. (10.1 mm) of airfoil is not to exceed 0.06 in. (1.5 mm) from original contour. Bulging of convex surface and concave side creases are acceptable, if no cracks on crease or bulge are present

Not repairable


o.

Blocked nose and gill air holes

Six nose holes, five convex surface gill holes, and eight concave surface gill holes. Any two adjacent holes may be blocked if adjacent two holes are open

Any number

Mechanically open holes




Inspect



1. Vane Airfoil for: - (cont.) p.

Blocked trailing edge air slots

Holes adjacent to each platform may be partially blocked, if they will accept a 0.025 in. (0.63 mm) pin

Not repairable


q.

Missing coating

Any amount, if burn and corrosion limits are met

Not repairable


NOTE Craze cracking is defined as numerous superficial surface cracks which have no measurable width or depth. r.

Craze cracking

Any amount

_

_

2. Outer Platform for: a.

Cracks in welds between vanes

0.63 in. (16.0 mm) length of weld

Not repairable


b.

Cracks in parent metal (excluding flanges and welds)

Any number, 0.85 in. (21.5 mm) long. See Note. One interconnecting crack between platform cooling holes is allowed. Cumulative length of all parent metal cracks including cracks in airfoil-toplatform fillet (step o.) is not to exceed 2.00 in. (50.8 mm)

Not repairable





Inspect



2. Outer Platform for: - (cont.) c.

Circumferential cracks on forward flange seal and trailing edge flange

Not serviceable

Not repairable


d.

Radial cracks on forward flange seal and trailing edge flange

One crack on forward flange, 0.25 in. (6.3 mm) long, one crack on trailing edge flange, 0.25 in. (6.3 mm) long, and any number, 0.100 in. (2.54 mm) long

Not repairable


e.

Radial cracks, propagating from outer flange cooling holes

Any number, max. 0.25 in. (6.3 mm) long. One crack, 0.40 in. (10.1 mm) long radially outward and one crack 0.40 in. (10.1 mm) long radially inward; one crack permitted to connect any cooling hole

Not repairable


f.

Nicks, scores, scratches, and dents on platform surfaces


Not repairable





Inspect



2. Outer Platform for: - (cont.) g.

Wear, rub marks, or galling of forward flange seal and trailing edge flange

h.

Burns or erosion (1)

Corrosion, erosion, and burns on vane platform

Any amount, 0.010 in. (0.25 mm) deep, after removal of high metal. Also, two wear areas may exist on forward flange faces, 0.60 in. (15.2 mm) long by 0.25 in. (6.3 mm) wide where thickness may be 0.036 in. (0.91 mm)

Not repairable


Any number. Burn through allowed. Loss of metal not to exceed 0.13 in. (3.3 mm) wide by 0.50 in. (12.7 mm) long

Not repairable


NOTE On borescope vane, erosion up to 0.13 in. (3.3 mm) on inside of borescope hole is acceptable. (2)

i.

Borescope hole


Not repairable


Cracks in insert-to-vane tack weld

One weld may be cracked at each insert

Not repairable





Inspect



2. Outer Platform for: - (cont.) j.

Plugged air holes (deposits)

Three per segment except in outer band leading edge where only one is allowed

Not repairable


k.

Erosion or missing material on aft flange seal

Any amount not exceeding 20 percent of circumferential length

Not repairable


l.

Cracks in aft flange seal lip

Axial cracks, any number, any length, 0.010 in. (0.25 mm) wide. Two circumferential cracks, 0.15 in. long (3.8 mm) are acceptable

Not repairable


Cracks in insert flange

Two per insert

Not repairable


n.

Seal slot breakthrough

Seal slot breakthrough is permitted only on aft side on trailing vane side surface

Not repairable


o.

Cracks in airfoil-toplatform fillet

Any number, 0.25 in. (6.3 mm) long. Cumulative length of all airfoil-toplatform fillet cracks and parent metal cracks (step b.) is not to exceed 2.00 in. (50.8 mm)

Not repairable


m.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 1 Nozzle Inspection - (Cont.)

Inspect




2. Outer Platform for: - (cont.) NOTE Scarfing is defined as grooves formed during manufacturing or repair, which are located adjacent to, and in-line with the cooling holes. p.

Scarfing on aft flange seal lip

Ten places, not more than 0.025 in. (0.63 mm) deep. One may have any amount, if no break through on gas flow side

Not repairable


q.

Missing coating

Any amount, if burn and erosion limits are met

Not repairable


NOTE Craze cracking is defined as numerous superficial surface cracks which have no measurable width or depth. r.

Craze cracking

Any amount

_

_

3. Inner Platform for: a.

Cracks between vane in weld

One half length of weld

Not repairable


b.

Cracks in parent metal (excluding flanges and welds)

Any number, 0.85 in. (21.5 mm) long. See Note. One inter connecting crack between platform cooling holes is allowed

Not repairable





Inspect



3. Inner Platform for: - (cont.) NOTE Cumulative length of all inner platform cracks, including cracks in airfoil-to-fillet area, is not to exceed 2.00 in. (50.8 mm). c.

Circumferential cracks on forward flanges

Not serviceable

Not repairable


d.

Radial cracks on forward seal

One crack, 0.25 in. (6.3 mm)

Not repairable


e.

Cracks on mounting flange except in weld between vanes

One crack, 0.25 in. (6.3 mm) long not emanating from or to mounting hole

Not repairable


f.

Nicks, scores, scratches, and dents on platform surfaces and flanges


Not repairable


g.

Wear, rub marks, or galling on forward flanges

Any amount, 0.010 in. (0.25 mm.) deep, after removal of high metal. Also, two wear areas may exist on forward flange, 0.60 in. (15.2 mm) long by 0.25 in. (6.3 mm) wide where thickness may be 0.036 in. (0.91 mm)

Not repairable





Inspect



3. Inner Platform for: - (cont.) h.

Plugged air holes (deposits)

Three per segment except in outer band leading edge where only one is allowed

Not repairable


i.

Corrosion, erosion, and burn on inner platform

Any amount. Burn through allowed. Loss of metal not to exceed 1.00 in. (25.4 mm) long by 0.25 in. (6.3 mm) wide

Not repairable


j.

Seal slot breakthrough

Permitted only on forward side of aft most slot and aft side of forward slot

Not repairable


k.

Missing coating

Any amount, if burn and erosion limits are met

Not repairable


l.

Metal voids (crack-like indications) in mounting flange on forward edge

Void in area A not to extend to hole. Voids in areas A, B, or C not to extend through flange

Not repairable

Replace nozzle segments

4. All areas for: a.

Metal splatter

Not serviceable

Not repairable


b.

Discoloration

Any amount

_

_

* May be repairable. Consult GE for disposition of replaced parts.




Figure 1. HPT Stage 1 Nozzle Assembly 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. HPT Stage 1 Nozzle Vanes 19 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 427 00 7.


High Pressure Turbine Stage 1 Nozzle Disassembly. a.

Place HPT stage 1 nozzle forward end down on working surface.

b.

Using marking pen, position mark HPT stage 1 nozzle segment vane with trailing edge closest in-line with 12:00 o’clock position as vane 1. NOTE Ensure single HPT stage 1 nozzle segment contains both vane 1 and vane 64.

c.

Indexing clockwise, aft looking forward (ALF), position mark remainder of HPT stage 1 nozzle segments.

d.

Using marking pen, matchmark forward windage cover segment (5, figure 1), baffle segments (3), inner and outer HPT stage 1 nozzle seals (7 and 8), and HPT stage 1 nozzle support (6) to HPT stage 1 nozzle assembly.

e.

Remove 18 shear bolts (4) that secure forward windage cover segment (5) and baffle segments (3) to HPT stage 1 nozzle support (6).

f.

Remove 18 baffle segments (3) and forward windage cover segment (5) from HPT stage 1 nozzle support (6). NOTE Ensure HPT stage 1 nozzle segments are properly supported during removal of HPT stage 1 nozzle support.

g.

Remove 64 shear bolts (2) and self-locking nuts (9) that secure HPT stage 1 nozzle segments (1) to HPT stage 1 nozzle support (6).

h.

Remove HPT stage 1 nozzle support (6) and place the 32 HPT stage 1 nozzle segments (1) on a working surface. Remove HPT stage 1 nozzle support (6).

i.

Disassemble HPT stage 1 nozzle as follows: (1)

Pull outer HPT stage 1 nozzle seal (8) radially outward enough to release one HPT stage 1 nozzle segment (1) runner.

(2)

Push HPT stage 1 nozzle segment (1) located adjacent to HPT stage 1 nozzle segment released in step (1) in axial direction until inner and outer nozzle seals (10 and 11) release from HPT stage 1 nozzle segment.

(3)

Tilt HPT stage 1 nozzle segment (1) to clear outer HPT stage 1 nozzle seal (8).




8.

(4)

Pull HPT stage 1 nozzle segment (1) radially outward from inner HPT stage 1 nozzle seal (7).

(5)

Repeat steps (1) through (4) to disassemble 31 remaining HPT stage 1 nozzle segments (1).

High Pressure Turbine Stage 1 Nozzle Reassembly. NOTE

•

HPT stage 1 nozzle is composed of 32 segments. Thirty one segments are the same, one segment contains a borescope port.

•

If same parts from paragraph 7. are being reassembled, use matchmarks and positions marks made during disassembly to aid in orientation during reassembly.

a.

Place inner HPT stage 1 nozzle seal (7, figure 1) on working surface, forward side down.

b.

Install runner of HPT stage 1 nozzle segment (1) containing borescope port into inner HPT stage 1 nozzle seal (7).

c.

Using pliers, tighten clips of inner HPT stage 1 nozzle seal (7) onto HPT stage 1 nozzle segment runner. NOTE Use petrolatum to aid in holding inner and outer nozzle seals in place during assembly.

d.

Install inner and outer nozzle seals (10 and 11) into counterclockwise end of HPT stage 1 nozzle segment (1).

e.

Place HPT stage 1 nozzle segment (1) into inner HPT stage 1 nozzle seal (7) about 0.250.50 in. (6.4-12.7 mm) counterclockwise from HPT stage 1 nozzle segment with borescope port.

f.

Move HPT stage 1 nozzle segment (1) clockwise to engage inner and outer nozzle seals (10 and 11). Ensure nozzle seals engage. NOTE Visually inspect inner and outer nozzle seals to ensure proper seating.

g.

Using soft mallet, gently tap HPT stage 1 nozzle segment (1) in clockwise direction until 0.031-0.063 in. (0.79-1.6 mm) gap between HPT stage 1 nozzle segments.




h.

Repeat steps d. through g. until 31 HPT stage 1 nozzle segments have been installed.

i.

Install last HPT stage 1 nozzle segment (1) as follows:

j.

(1)

Install inner and outer nozzle seals (10 and 11) into counterclockwise end of HPT stage 1 nozzle segment (1).

(2)

Using soft mallet, gently tap HPT stage 1 nozzle segments (1), between which last HPT stage 1 segment will fit, away from gap in segments.

(3)

Using extreme care, gently insert last HPT stage 1 segment into inner HPT stage 1 nozzle seal (7).

Using soft mallet, gently tap all HPT stage 1 nozzle segments (1) to seat runners into inner HPT stage 1 nozzle seal (7). NOTE In free state, assembled HPT stage 1 nozzle segments and inner HPT stage 1 nozzle seal are not concentric.

k.

Temporarily secure outer circumference of HPT stage 1 nozzle assembly until HPT stage 1 nozzle support (6) can be installed.

l.

If required, position mark HPT stage 1 nozzle vane No. 1 as follows: (1)

Locate HPT stage 1 nozzle segment (1) with borescope vane.

(2)

Indexing counterclockwise, ALF, count 18 vanes from vane located at top of borescope port segment.

(3)

Using marking pen, position mark vane trailing edge as top centerline. NOTE

•

Each HPT stage 1 nozzle segment has two mounting tabs. All right, ALF, mounting tabs have sleeve installed.

•

HPT stage 1 nozzle segment with borescope port has sleeve installed in both left and right mounting tabs.

m. Place HPT stage 1 nozzle support (6), forward end down, inside assembled HPT stage 1 nozzle assembly.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines n.

Align TOP mark on HPT stage 1 nozzle support (6) with HPT stage 1 nozzle segment (1) vane trailing edge position marked as top centerline vane. NOTE With TOP mark on HPT stage 1 nozzle support and top centerline vane aligned, all holes in mounting tabs of HPT stage 1 nozzle segments shall be aligned. Sleeves in mounting tabs shall engage holes in HPT stage 1 nozzle support.

o.

Using thread lubricant, lightly coat threads of 64 shear bolts (2) and contact faces of 64 self-locking nuts (9).

p.

Using 64 shear bolts (2), boltheads aft, and self-locking nuts (9), secure 32 HPT stage 1 nozzle segments (1) to HPT stage 1 nozzle support (6). Tighten bolts finger-tight.

q.

While holding HPT stage 1 nozzle segments radially inward, tighten bolts to final torque of 110-120 lb in. (12.5-13.5 N⋅m) of torque.

r.

Install 18 baffle segments (3) onto aft side of HPT stage 1 nozzle support (6).

s.

Using thread lubricant, lightly coat threads of shear bolts (4).

t.

Using 18 shear bolts (4) and three forward windage cover segments (5), secure 32 HPT stage 1 nozzle segments (1) to HPT stage 1 nozzle support (6). Tighten bolts to 90-100 lb in. (10.2-11.3 N⋅m) of torque.

u.

Install outer HPT stage 1 nozzle seal as follows: (1)

Remove temporary restrain from outer circumference of HPT stage 1 nozzle assembly.

(2)

Place outer HPT stage 1 nozzle seal (8) on working surface, forward side down.

(3)

Place HPT stage 1 nozzle support (6) inside outer HPT stage 1 nozzle seal (8).

(4)

Raise and align outer HPT stage 1 nozzle seal (8) with runner on outside diameter of HPT stage 1 nozzle segment at 12:00 o’clock position.

(5)

Using soft mallet, gently tap outer HPT stage 1 nozzle seal (8) onto HPT stage 1 nozzle segment (1) until fully seated.

(6)

Indexing clockwise, ALF, seat outer HPT stage 1 nozzle seal (8) onto remaining 31 HPT stage 1 nozzle segments. Ensure outer HPT stage 1 nozzle seal is fully seated.


GEK 105054 Volume II WP 427 00 (7) 9.

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Using soft mallet, gently tap outer HPT stage 1 nozzle seal (8), as required to center HPT stage 1 nozzle assembly.

High Pressure Turbine Stage 1 Nozzle Open Area (A4) Inspection. NOTE Measurement of the open area (A4) is only required if more than six HPT stage 1 nozzle segments are replaced.. a.

Prepare HPT nozzle open area gage, 2C6505, as follows: (1)

Pull lower finger lock (4, figure 3) to unlock lower finger (5) assembly.

(2)

Rotate thumb lever stop (7) to release thumb lever (2).

(3)

Depress thumb lever (2). NOTE

Hold open area indicator up while install finger assembly onto set master.

b.

(4)

Hook lower finger (5) assembly on lower trailing edge of set master (6).

(5)

Using rolling motion, engage upper finger (10) assembly under upper trailing edge of set master (6).

(6)

Release thumb lever (2).

(7)

Slightly rock HPT nozzle open area gage, 2C6505, from side to side to ensure ball contact (8) is seated against side rail of set master (6).

(8)

Adjust open area indicator (1) bezel so large pointer indicates 34.

Using HPT nozzle open area gage, 2C6505, measure HPT stage 1 nozzle as follows: (1)

Starting at No. 1 vane position, install HPT nozzle open area gage, 2C6505, onto HPT stage 1 nozzle as follows: (a) Depress thumb lever (2). (b) Position lower finger (5) assembly under trailing edge of vane. (c) Position upper finger (10) assembly under trailing edge of adjacent vane.




(d) Rock HPT nozzle open area gage, 2C6505, forward until all probes make positive contact. Simultaneously, slide gage toward outer platform of vane segment until locating ball contact (8) contacts inside diameter (ID) of outer platform. (e) Release thumb lever (2) and HPT nozzle open area gage, 2C6505.

c.

d.

(2)

Tap lightly on HPT nozzle open area gage, 2C6505, to ensure constant reading and repeatability.

(3)

Read open area indicator (1).

(4)

Record reading in table 2.

(5)

Repeat steps (1) through (4) for all HPT stage 1 nozzle vanes. Recalibrate HPT nozzle open area gage, 2C6505, per step a. every 10 vanes checked.

Total flow area shall be 53.452 - 54.452 square in. (344.85 - 351.30 cm2). (1)

If total flow area is not within limits, replace HPT stage 1 vane nozzle segments, as required, to meet limits.

(2)

If total flow area specifications cannot be met, replace HPT stage 1 nozzle.

When not in use, maintain HPT nozzle open area gage, 2C6505, as follows: (1)

Ensure HPT nozzle open area gage, 2C6505, is stored away from dust, moisture, grit, and lubricants.

(2)

Using clean dry shop air, clean HPT nozzle open area gage, 2C6505, if mechanism becomes sluggish.

(3)

Recalibrate set master annually. Contact GE M&I for specific instructions on source of annual calibration.




Figure 3. HPT Nozzle Open Area Gage, 2C6505 (Sheet 1 of 2) 26 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. HPT Nozzle Open Area Gage, 2C6505 (Sheet 2 of 2)



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 2. HPT Stage 1 Nozzle Open Area Work Sheet

Nozzle Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Sub Total

Open Area

Nozzle Number 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 Sub Total

Open Area

Total Open Area = __________________________________________




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE TURBINE STAGE 2 NOZZLE INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Turbine Stage 2 Nozzle Inspection............................................................

3


GEK 105054 Volume II WP 428 00 1.


Introduction. This work package provides instructions for the inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, high pressure turbine (HPT) stage 2 nozzle assembly.

2.


Number

Operation and Maintenance Manual, Volume II High Pressure Turbine Stage 2 Nozzle Assembly Replacement

GEK 105054

3.


4.


5.

SWP 201 01

Nomenclature


Weld Filler Material

AMS 5786





High Pressure Turbine Stage 2 Nozzle Inspection. CAUTION

a.

•

IF ANY HPT INTERSTAGE AIR SEAL SEGMENT REQUIRES REPLACEMENT, HPT STAGE 2 NOZZLE ASSEMBLY SHALL BE REPLACED.

•

IF ANY HPT STAGE 1 OR 2 SHROUD SEGMENT REQUIRES REPLACEMENT, HPT STAGE 2 NOZZLE ASSEMBLY SHALL BE REPLACED.

Inspect HPT stage 2 nozzle per table 1 and figure 1. Table 1. HPT Stage 2 Nozzle Assembly

Inspect



COOLING AIR TUBES 1. All Areas for: a. Cracks Not serviceable Not repairable b. Wear Not serviceable Not repairable HPT STAGE 2 NOZZLE SUPPORT ASSEMBLY 1. All Body Surface Area for: a. Cracks Not serviceable Not repairable

b.

Nicks and scratches

c.

Bulges and dents

d.

Plugged cooling air holes

Any number, any length 0.016 in. (0.40 mm) deep. Remove high metal from mating surfaces Three bulges or dents, 0.50 in. (12.7 mm) diameter, 0. 19 in. (4.8 mm) deep. No high metal allowed on mating surfaces Not serviceable

Not repairable


Replace cooling tube Replace cooling tube

Replace HPT stage 2 nozzle per SWP 201 01 Replace HPT stage 2 nozzle per SWP 201 01

Any amount that will not affect assembly

Bench high metal on mating flanges mating surfaces or replace part

Any number

Clear holes



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPT Stage 2 Nozzle Assembly - (Cont.)

Inspect




2. HPT Stage 2 Nozzle Support Flange for: a.


Not serviceable

Not repairable

Replace HPT stage 2 nozzle per SWP 201 01

b.

Radial cracks

Two radial cracks from boltholes inward, if separated by minimum of five boltholes

Not repairable


c.

Nicks and scratches

Any number, any length 0.016 in. (0.40 mm) deep, after removal of high metal from mating surface

Not repairable


d.

Missing or chipped thermal sprayed coating

10 percent may be missing

Not repairable


3. Rear Mounting Flange for: a.

Cracks extending from boltholes to edge of flange

Two radial cracks, if separated by minimum of five boltholes

Not repairable


b.


Any number, 0.020 in. (0.50 mm) deep, after removal of high metal. Shall not extend more than 75 percent across surface

Not repairable





Inspect




4. Air Seal for: a.

Wear on wear strip

0.020 in. (0.50 mm) deep, if outside diameter (OD) is not less than 18.223 in. (462.86 mm) radius

Any amount

Re-form air seal to 36.446 in. (925.72 mm) diameter at wear strip or replace HPT rotor and HPT stage 2 nozzle

b.

Loose tack weld at support to seal junction

Not serviceable

Any amount

Tack-weld

c.


Not serviceable

Not repairable


d.

Axial cracks in saw cuts

One per saw cut, 0.25 in. (6.3 mm) long

Not repairable


e.

Deformed wear strip

Not serviceable

Any amount, if weld is sound

Straighten or hand blend to smooth contour

f.

Deformed, missing, or worn seal strips or clips

Any amount not worn through. No loose or missing clips. Deformation allowed, if slot is sealed

Not repairable


g.

Burns or erosion

Not serviceable

Not repairable


5. Shroud Stop for: a.

Cracks

Not serviceable

Not repairable


b.

Wear


Not repairable





Inspect




6. Ferrule for: a.

Nicks and scratches


Not repairable


b.

Tack weld loose

One tack weld loose per ferrule

Any amount

Weld using AMS 5786 filler material

5 percent may be missing

Not repairable


7. Surface AV for: a.

Missing hard coat

FORWARD STAGE 2 SHROUD SUPPORT 1. All Areas for: a.


Not serviceable

Not repairable

Replace forward shroud support segment

b.

Radial cracks

Two cracks from bolthole to OD of support. One crack at slot, 0.38 in. (9.6 mm) long

Not repairable


c.

Wear on mounting support

Any amount, 0.010 in. (0.25 mm) deep up to 1.00 in. (25.4 mm) from ends, 0.030 in. (0.76 mm) deep

Not repairable


d.

Distortion

Not serviceable

Any amount, if no cracks result from rework





Inspect




AFT STAGE 2 SHROUD SUPPORT 1. Area G for: a.

Cracks from boltholes

Ten cracks, 0.25 in. (6.3 mm) long, if crack does not connect with slot

Not repairable

Replace aft shroud support

b.

Cracks from slot hole

One per slot, 0.25 in. (6.3 mm) long two per slot 0.150 in. (3.81 mm) long

Not repairable


c.

Cracks in plate

Ten cracks, 0.25 in. (6.3 mm) long

Not repairable


d.

Wear

Any amount, 0.005 in. (0. 12 mm) deep

Not repairable


2. Aft Mounting Supports for: a.

Cracks

Three axial cracks, 0.25 in. (6.3 mm) long separated by at least 2.0 in. (50.8 mm). No circumferential cracks allowed

Not repairable


b.

Wear on shroud track mating surface

Any amount, 0.010 in. (0.25 mm) deep, after removal of high metal

Not repairable


c.

Corrosion or burning

0.020 in. (0.50 mm) deep in area not greater than 0.25 in. (6.3 mm) by 0.25 in.(6.3 mm), 11 areas maximum

Not repairable





Inspect




HPT STAGE 2 SHROUD 1. Mounting Supports for: a.

Cracks

Accept axial cracks if spaced 6.00 in. (152.4 mm) apart and do not extend into radial rib

Not repairable


b.

Wear on mating surface

Any length, 0.005 in. (0. 12 mm) deep, 0.010 in. (0.25 mm) deep for total length of 1.00 in. (25.4 mm)

Not repairable


c.

Bent edge on support

Not serviceable

0.06 in. (1.5 mm) from original for cracks

Mechanically straighten. Inspect contour

d.

Dents

0.020 in. (0.50 mm) deep, if it can be assembled

Dents up to 1.00 in. (25.4 mm) long are acceptable, if removal of protrusion does not thin flange to less than 50 percent of original flange thickness

Remove protrusion by blending

e.

Nicks and scores




f.

Distortion and/or waviness

Acceptable if proper assembly can be accomplished

Not repairable


Not serviceable

Not repairable


2. Backing Strip for: a.





Inspect




2. Backing Strip for: - (Cont.) b.

Axial cracks in backing strips

One crack per segment 0.50 in. (12.7 mm) long; four cracks per segment 0.25 in. (6.3 mm) long

Not repairable


c.

Nicks, dents, and scores


Not repairable


3. Abradable Surface for: a.

Wear track

0.25 in. (6.3 mm) segment

Not repairable


b.

Positive metal due to blade rub

0.010 in. (0.25 mm) metal build up on two shroud segments per assembly

Any amount, if not more than 0.025 in. (6.3 mm) into abradable surface, after removal of positive metal

Blend

c.

Erosion or damage

0.050 in. (1.27 mm) deep, accumulation up to 30 percent of surface

Not repairable


d.

Loosened or missing filler exposing backing strip

75 percent in row of honeycomb cells adjacent to both forward and aft rails and 50 percent in the first and second row of honeycomb cells adjacent to both side plates. Three may be missing or loose at other places

Not repairable





Inspect




4. Gas Face for:

a.

Radial cracks

Three per segment, 0.20 in. (5.0 mm) long, separated by 0.50 in. (12.7 mm)

Not repairable


b.

Erosion and/or missing metal

0.020 in. (0.50 mm) deep by 2.00 in. (50.8 mm) long

Not repairable


c.


Two per segment, 0.100 in. (2.54 mm) long, if they do not intersect radial cracks

Not repairable


0.020 in. (0.50 mm) deep, full length of segment, or 0.03 in. (0.7 mm) deep, 4.00 in. (101.6 mm) long per segment

Not repairable


5. Filled Honeycomb for: a.

Wear track

NOTE The cumulative total of all axial and circumferential areas of damage shall not exceed 1.00 sq in. (25.4 sq mm) per shroud segment. b.

Axial damage

Any number of scores not extending into backing strip, if cumulative total areas for damage does not exceed 1.00 sq in. (6.4 cm2) per segment or 2.00 sq in. (12.9 cm2) cumulative for entire shroud assembly

Not repairable





Inspect




5. Filled Honeycomb for: - (cont.) c.

Circumferential damage caused by foreign objects

Any amount, if no one area of damage exceeds 0.10 in. (2.5 mm) wide for entire length of shroud segment or 0.20 in. (5.0 mm) wide per shroud segment and does not extend into backing strip

Not repairable


d.

Missing filler exposing backing strip

A total of 65 cells may be missing or 75 percent in row of honeycomb cells adjacent to both forward and aft rails and 50 percent in the first and second row of honeycomb cells adjacent to both side plates

Not repairable


e.

Cracks in abradable material

Any number, 0.50 in. (12.7 mm) long, if cumulative length does not exceed 1.50 in. (38.1 mm)

Not repairable


Not repairable


INTERSTAGE STATIONARY AIR SEAL 1. Honeycomb for: a.

Annular wear groove

One per groove, 0.25 in. (6.3 mm) wide, not to exceed 0.13 (3.3 mm) deep




Inspect




1. Honeycomb for: - (cont.) b.

Corner cell ribs dented or bent

Section of first cell rib may be dented 1.00 in. (25.4 mm) long, second cell rib 0.75 in. (19.0 mm) long

Not repairable


c.

Cell damage/ erosion

Any number of isolated cell areas of 0.50 in. (12.7 mm) square

Not repairable


2. Housing for: a.

Axial cracks

Two axial cracks, 1.00 in. (25.4 mm) long, not within 2.0 in. (50.8 mm) of end

b.


Not serviceable

Not repairable


c.

Damage or distortion at cooling slots

Any amount. No cracks allowed

Not repairable


STAGE 1 TURBINE SHROUDS 1. Mounting Supports for: a.

Cracks

Accept axial cracks if spaced 6.00 in. (152.4 mm) apart and do not extend into radial rib

Not repairable


b.

Wear on mating surface

Any length, 0.005 in. (0.12 mm) deep, 0.010 in. (0.25 mm) deep for total length of 1.00 in. (25.4 mm)

Not repairable





Inspect




1. Mounting Supports for: - (cont.) c.

Bent edge on support

Not serviceable

0.06 in. (1.5 mm) from original contour


d.

Dents

0.020 in. (0.50 mm) deep, if it can be assembled

Dents up to 1.00 in. (25.4 mm) long are acceptable, if removal of protrusion does not thin flange to less than 50 percent of original flange thickness

Remove protrusion by blending

e.

Nicks and scores



Blend to remove

f.

Distortion and/or waviness

Acceptable, if proper assembly can be accomplished

Not repairable




Not serviceable

Not repairable


b.

Axial cracks in backing strips

One crack per segment, 0.50 in. (12.7 mm) long; four cracks per segment 0.25 in. (6.3 mm) long

Not repairable


c.



Not repairable





Inspect




3. Abradable Surface for: a.

Wear track

0.25 in. (6.3 mm) deep full length of segment

Not repairable


b.

Positive metal due to blade rib

0.010 in. (0.25 mm) metal buildup on two shroud segments per assembly

Any amount, if not more than 0.025 in. (6.3 mm) into abradable surface after removal of positive metal

Blend

c.

Erosion or damage at shroud edges

0.10 in. (2.54 mm) deep, accumulation up to 10 percent of surface

Not repairable

Replace HPT rotor and HPT stage 2 nozzle

d.

Erosion/ burning exposing backing strip

Not serviceable

Not repairable


4. Gas Face for: a.

Radial cracks

Three per segment, 0.20 in. (5.0 mm) long, separated by 0.50 in. (12.7 mm)

Not repairable


b.

Erosion and/or missing metal

0.020 in. (0.50 mm) deep by 2.00 in. (50.8 mm) long

Not repairable


c.


Two per segment, 0.100 in. (2.54 mm) long, if they do not intersect with radial cracks

Not repairable





Figure 1. HPT Stage 2 Nozzle Assembly (Sheet 1 of 2) 15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 1. HPT Stage 2 Nozzle Assembly (Sheet 2 of 2) 16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



WORK PACKAGE

TECHNICAL PROCEDURES TURBINE MID FRAME INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Turbine Mid Frame Inspection...........................................................................................

3


GEK 105054 Volume II WP 429 00 1.


Introduction. This work package provides instructions for inspection of the LM2500+ Models GK and GV gas generator, and Models PK and PV gas turbine, turbine mid frame (TMF).

2.


Number

Operation and Maintenance Manual, Volume II Turbine Mid Frame Replacement

GEK 105054 WP 200 00

3.


4.


5.





Turbine Mid Frame Inspection a.


b.

Inspect TMF per table 1 and figures 1 through 4. Table 1. Turbine Mid Frame Inspection On-Site Maximum Serviceable Limits

Inspect



CASE 1. Specific Areas to be Inspected for Cracks: a.

b.

Indications in weld/heat affected zone areas

Indications in parent metal (outside weld/heat affected zone)

Indication no longer than 0.10 inch (2.5 mm)

Not repairable


Indications confined to weld or heat affected zone within 0.10 inch (2.5 mm) of weld line

Not repairable


Indications transverse to weld line in heat affected zone

Not repairable


Min spacing between indications: two times max adjacent indication dimension

Not repairable


Indications no longer than 0.030 inch (0.78 mm)

Not repairable


Indications 0.030 to 0.060 inch (0.76 to 1.52 mm) long, not interpreted as cracks

Not repairable




LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. Turbine Mid Frame Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect



1. Specific Areas to be Inspected for Cracks: - (cont.) Indications in parent metal (outside weld/heat affected zone) (cont.)

Min spacing between indications: two times max adjacent indication dimension

Not repairable


2. Hat Sections (Fore and Aft) for: a.

Fillet weld cracks

Not serviceable in excess of limits in 1. above

Not repairable


b.

Seam weld cracks

Not serviceable in excess of 2.0 inches (50.8 mm) per segment

Not repairable


c.

Parent metal cracks (neutral areas only

Not serviceable in excess of limits in 1. above

Not repairable


Not serviceable

Not repairable


Not serviceable

Not repairable


Not serviceable

Not repairable


3. Forward Flange for: a.

Circumferential weld cracks

4. Aft Flange for: a.

Circumferential weld cracks

5. Casing Strut Pads for: a.

Butt weld cracks

6. Instrumentation (T5.4 and P5.4) Bosses for: a.

Cracks

One crack, 0.25 inch (6.3 mm) long. One boss per frame may be cracked

Not repairable


b.

Thread damage

Not serviceable

One complete thread may be removed

Chase threads




Inspect



7. All Other Casing Areas for: a.

Axial welds/parent metal cracks

Not serviceable

Not repairable


b.


Any number, any length, 0.016 inch (0.40 mm) deep after removal of high metal, if defects do not cross completely across sealing surface

Not repairable


c.

Dents

Any number smooth contour dents 0.25 inch (6.3 mm) deep, except on interface sealing surface

Not repairable


d.

Local distortion

Any number, 0.20 inch (5.0 mm) deep, except on interface sealing surface

Not repairable


8. Case Strut Pads for: a.

Cracks

Not serviceable

Not repairable


b.

Bent lugs

Not serviceable

Not repairable





Inspect



LINER 1. All Surfaces (Unless Otherwise Specified) for: a.


Any number, not exceeding 2.0 inches (50.8 mm) length, and not joining with adjacent cracks. Monitor for crack propagation by borescope inspection at each opportunity, but not later than 500 hours of operation

Not repairable


b.

Missing material

Not serviceable

Not repairable


c.


Any amount, 0.25 inch (6.3 mm) from original contour, 0.125 inch (3.17 mm) buckles on leading edge

Not repairable


d.


Any number, any length, 0.016 inch (0.40 mm) deep, after removal of high metal

Not repairable


e.

Dents

Any number smooth contour dents 0.25 inch (6.3 mm) deep, except on sealing surface or surface evidencing hot spots

Not repairable


f.

Hot spots

Serviceable, if metal not crazed

Not repairable





Inspect



1. All Surfaces (Unless Otherwise Specified) for: - (cont.) g.

Wear on ID of fairing

50 percent of stock thickness

Not repairable


2. Inner Rear Seals for: a.

Gap at seal opening

1.0 sq in. (25.4 sq mm) max

Any amount

Re-form seal

b.

Broken or missing segments

Not serviceable

Not repairable


3. Liner Deflectors for: a.

Missing deflector

Not serviceable

Not repairable


b.

Cracked or broken deflector

Not serviceable

Not repairable


Not serviceable

Not repairable


Not repairable


Not repairable


STRUT END CAPS 1. Gasket for: a.

Visible damage to gasket or loss of gasket material

2. Flanges (Cap and Tube) and Cap Lugs for: a.

Distortion, outof-flat flange and bent cap lugs

Not serviceable

LINER SUPPORT 1. All Areas Unless Otherwise Specified for: a.

Cracks (1)

Inner Support

Not serviceable




Inspect



1. All Areas Unless Otherwise Specified for: - (cont.) (2)

Outer Support

Accept one crack per bolthole 0.50 inch (12.7 mm) long, provided cracked boltholes are separated by one uncracked hole

Not repairable


b.


Any number, any length 0.016 inch (0.40 mm) deep, after removal of high metal

_

Blend

c.

Dents

Any number smooth contour dents 0.125 inch (3.17 mm) deep, except on mating (sealing) surface

Not repairable


2. Liner Support Stops (For Stage 2 HPT Shroud) for: a.

Cracks

Not serviceable

Not repairable


b.

Missing stops

Maximum of 44 stops may be missing if no more than 6 are adjacent

Not repairable


c.

Bent

Not serviceable

Not repairable


3. Swaged Bushing for: a.

Cracks

Not serviceable

Not repairable


b.

Wear at strut pad/case holes

Local fretting or grooving up to 0.010 inch (0.25 mm) deep

Not repairable





Inspect



3. Swaged Bushing for: - (cont.) c.


Not serviceable

Any amount

Remove high metal using fine file or stone

C-SUMP HOUSING 1. No. 5 Bearing Housing Bore for: a.

Wear and outer surface distress (nicks, scratches, and dents)

Any number, 0.010 in. (0.25 mm) deep max, after removal of high metal

Not repairable


b.

Surface damage

Same as a.

Not repairable


2. No. 6 Bearing Housing Bore for: (LM2500+ Model PK Only) a.

Wear and outer surface distress (nicks, scratches, and dents)

Any number, 0.010 in. (0.25 mm) deep max, after removal of high metal

Not repairable


b.

Surface damage

Same as a.

Not repairable


AFT OUTER AIR SEAL (LM2500+ Model PK only) 1. Flange for: a.

Cracks

One crack per bolthole from hole to outer edge of flange; max of 12 holes. No more than 3 holes in a row with cracks. No missing pieces allowed

Not repairable

Replace seal




Inspect



1. Flange for: - (cont.) b.


Any number, 0.020 inch (0.50 mm) deep, after removal of high metal

Not repairable

Replace seal

c.

Wear

0.005 inch (0.12 mm) deep

0.010 inch (0.25 mm) deep

Blend smooth

d.

Distortion

0.020 inch (0.50 mm) out-ofcontour maximum of 2.0 inches (50.8 mm) in individual area, total not to exceed 10 inches (254 mm) provided proper assembly can be accomplished

Not repairable

Replace seal


Cracks

Any number axial cracks 0.5 inch (12.7 mm) long and 1.0 inch (25.4 mm) apart, not across edges

Not repairable

Replace seal

b.


Any number, 0.020 inch (0.50 mm) deep

Not repairable

Replace seal




Inspect



2. Backing Strip for: - (cont.) c.

Distortion

0.0625 inch (1.587 mm) out-ofcontour, maximum of 4.0 inches (101.6 mm) in individual area, total not to exceed 20 inches (508 mm), if proper assembly can be accomplished

Not repairable

Replace seal

3. Honeycomb for: a.

Wear

Track not to exceed 0.150 inch (3.81 mm) maximum depth, any width. Track may run off edge of honeycomb

Not repairable

Replace seal

b.


Not to exceed 10 percent of total circumferential length 25 percent of honeycomb width and not into backing strips after removal of folded edges

Not repairable

Replace seal

c.

Loose or unbonded cells

Not serviceable

Not repairable

Replace seal




Inspect



LOW PRESSURE TURBINE (LPT) NOZZLE SUPPORT (LM2500+ MODEL PK ONLY) 1. All Surfaces Unless Otherwise Specified for: a.

Cracks

Not serviceable

Not repairable


b.

Nicks or scores

Any number, any length, 0.0156 inch (0.396 mm) deep, after removal of high metal

Not repairable


c.

Dents

Any number smooth contour dents 0.125 inch (3.17 mm) deep

Not repairable


2. Seal for: a.

Distortion

Any amount, provided mating part can be assembled

Any amount

Re-form

b.

Wear

50 percent of stock thickness

Not repairable


Not serviceable

Not repairable


3. Safety Wire Tabs for: a.

Broken/ missing

OUTER NOZZLE SUPPORT (LM2500+ MODEL PK ONLY) 1. Pins for: a.

Loose or missing

Not serviceable

Not repairable

Replace outer nozzle support

b.

Bent

Not serviceable

Any amount

Straighten pin




Inspect



2. All surfaces for: a.

Axial and radial cracks

Any number, any length in axial or radial direction. Radial cracks may sever support if each remaining segment contains a minimum of two counter-sunk. screw holes used to mount nozzle support to TMF

Not repairable

Replace aft ring

b.


Not serviceable

Not repairable

Replace aft ring

c.

Distortion

Acceptable if proper assembly can be made

Not repairable

Replace aft ring

d.

Nicks and scores

Any number, 0.0312 inch (0.792 mm) deep, remove high metal

Not repairable

Replace support

e.

Dent

Any number, 0.0312 inch (0.792 mm) deep

f.

Wear

0.010 inch (0.25 mm) deep on outside diameter (OD) of axial flange, 0.095 inch (2.41 mm) minimum flange thickness

0.020 inch (0.50 mm) deep on OD of axial flange

Blend smooth

HPT ADAPTER (LM2500+ MODELS GK, GV, AND PV ONLY) 1. All Areas for: a.

Cracks

Not serviceable

Not repairable

Replace HPT adapter




Inspect



2. Mating Surfaces for: a.


Not serviceable

Any amount

Remove high metal

b.


Any number, any length, 0.030 in. (0.76 mm) deep, after removal of high metal, if defect does not extend completely across mating surface

Any number

Blend to original contour

Ten holes, but not more than two adjacent boltholes

Any amount, but not more than four adjacent boltholes

Replace HPT adapter

3. Boltholes for: a.

Outer flange bolthole cracks

4. Gang Channel Nuts for: a.

Loose or unseated retaining screws

Not serviceable

Any number

Tighten screw or replace screw. Screwhead not to extend beyond flange surface

b.

Loss of self locking quality or missing nuts

Not serviceable

Any number

Replace HPT adapter

Any number not exceeding 3.0 in. (76 mm) length

Replace aft cover

AFT COVER (LM2500+ Model GK Only) 1. All Areas for: a.

Cracks

Not serviceable




Inspect



2. Mating Surface for: a.


Not serviceable

Any amount

Remove high metal

b


Any number, any length, 0.030 in.(0.76 mm) deep, after removal of high metal, if defect does not extend completely across mating surface

Any number


Ten holes max, but not more than two cracks adjacent boltholes

Any amount, but not more than four adjacent boltholes

Replace aft cover

3. Boltholes for: a.

Outer flange bolthole cracks




Figure 1. TMF-LM2500+ Model GK Only 16 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. TMF-LM2500+ Model PK Only 17 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. TMF-LM2500+ Models GV and PV Only 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 4. TMF Casing-to-Casing Butt Weld Areas




WORK PACKAGE

TECHNICAL PROCEDURES HIGH PRESSURE COMPRESSOR VARIABLE STATOR VANE SHROUDS INSPECTION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject High Pressure Compressor Variable Stator Vane Shrouds Inspection............................

3


GEK 105054 Volume II WP 430 00 1.


Introduction. This work package provides instructions for the inspection of the high pressure compressor (HPC) variable stator vane (VSV) shrouds.

2.


Number

Operation and Maintenance Manual, Volume II High Pressure Compressor Stator Casings Replacement High Pressure Compressor Variable Stator Vane Shrouds Replacement

GEK 105054 WP 211 00

3.


4.


5.


WP 213 00




High Pressure Compressor Variable Stator Vane Shrouds Inspection. a.

Remove HPC stator casings per WP 211 00.

b.

Remove VSV shrouds per WP 213 00. NOTE The front and rear halves of each VSV shroud 180 degree segment are machined as an assembly, and shall be maintained as matched sets.

c.

Inspect VSV shrouds per table 1. Table 1. HPC VSV Shrouds Inspection On-Site Maximum Serviceable Limits

Inspect



1. Inlet Guide Vane (IGV), Stage 0, Stage 1, and Stage 2 Shrouds for: a.

Cracks

Not serviceable

Not repairable

Replace shrouds

b.

Nicks and scratches

Any number, 0.0156 in. (0.396 mm) deep, after removal of high metal, with 0.030 in. (0.76 mm) minimum radius at bottom

Any number, 0.030 in. (0.76 mm) deep, 2.0 in. (50.8 mm) long, with 0.030 in. (0.76 mm) minimum radius at bottom

Remove high metal, blend out with 0.030 in. (0.76 mm) minimum radius tool, or replace shroud

c.

Dents

Any number, 0.0625 in. (1.587 mm) deep, if there are no sharp edges or abrupt change in contour

Not repairable

Replace shroud

d.

Distortion (warped)

Acceptable, if they can be properly assembled, do not interfere with VSV operation, and specified rotor clearances can be maintained

Not repairable

Replace shroud



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Table 1. HPC VSV Shrouds Inspection - (Cont.) On-Site Maximum Serviceable Limits

Inspect



1. IGV, Stage 0, Stage 1, and Stage 2 Shrouds for: - (cont.) e.

Variable vane tip rub on shroud outside diameter (OD)

Any amount, 0.0156 in. (0.396 mm) deep, after removal of high metal

Not repairable

Remove high metal or replace shroud

f.

Seal rub

0.015 in. (0.38 mm) deep, full circumference


Remove high metal or replace shroud

g.

Fretting on end faces


Any amount

Remove high metal

h.

IGV shroud forward lip inside diameter (ID) wear

Any amount to 0.045 in. (1.14 mm) min wall thickness

Not repairable

Replace shroud




WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE THRUST BALANCE CAVITY PRESSURE SYSTEM ORIFICE PLATE SELECTION (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 8 ................... 0


Page

Power Turbine Thrust Balance Cavity Pressure System Orifice Plate Selection. ..........

3


GEK 105054 Volume II WP 431 00 1.


Introduction. This work package provides instructions for selecting proper size power turbine (PT) thrust balance cavity pressure system orifice plate to maintain engine within preferred operating range. The orifice plate is used to adjust the thrust balance cavity pressure.

2.

3.


Number

Operation and Maintenance Manual, Volume I LM2500 + SAC System Description Installation/Initial Startup and Engine Operation Operation and Maintenance Manual, Volume II General Maintenance Practices Illustrated Parts Breakdown

GEK 105054 Chapter 5 Chapter 7 GEK 105054 WP 002 00 GEK 105055

Support Equipment. Nomenclature Excel worksheet - No.7B Trust Balance Orifice Selection

4.

5.

Part No. -



Thread Lubricant



IPB Figure No./Item

Orifice Plate Square Seal Gasket

44-57 44-56




Power Turbine Thrust Balance Cavity Pressure System Orifice Plate Selection. NOTE

•

Maintenance of PT thrust balance cavity pressure in the preferred operating range is required to ensure No. 7B bearing life. Refer to GEK 105054, Volume I, Chapter 5, for monitoring requirements.

•

During initial buildup of gas turbine, PT thrust balance cavity pressure is adjusted into operating range with the proper size orifice plate. Due to changes in balance piston seal leakage, periodic orifice sizing and adjustment of PT balance piston system cavity pressure are required.

a.


b.

Check and record part number of PT balance piston system orifice plate (3, figure 1). Determine corresponding orifice plate size from table 1.

c.

Use PT thrust balance cavity pressure tap (figure 2) located on turbine rear frame (TRF) number 2 strut. If tap is not already in use, remove cap and install suitable high temperature hose with 0-200 psia (0-1379.0 kPa) range gage or transducer attached. Tighten hose B-nut to 180-200 lb in. (20.4-22.5 N⋅m) of torque. Table 1. PT Balance Piston Orifice Plate Size Part No. 1792M79P01 1792M79P02 1792M79P03 1792M79P04 1792M79P05 1792M79P06 1792M79P07 1792M79P08 1792M79P09 1792M79P10 1792M79P11 1792M79P12 1792M79P13 1792M79P14 1792M79P15 1792M79P16 1792M79P17 1792M79P18

Orifice Diameter 0.495-0.505 inch 0.515-0.525 inch 0.545-0.555 inch 0.575-0.585 inch 0.605-0.615 inch 0.635-0.645 inch 0.665-0.675 inch 0.695-0.705 inch 0.725-0.735 inch 0.755-0.765 inch 0.785-0.795 inch 0.815-0.825 inch 0.845-0.855 inch 0.875-0.885 inch 0.905-0.915 inch 0.935-0.945 inch 0.965-0.975 inch 0.995-1.005 inch

(12.58-12.82 mm) (13.09-13.33 mm) (13.85-14.09 mm) (14.61-14.85 mm) (15.37-15.62 mm) (16.13-16.38 mm) (16.90-17.14 mm) (17.66-17.90 mm) (18.42-18.66 mm) (19.18-19.43 mm) (19.94-20.19 mm) (20.71-20.95 mm) (21.47-21.71 mm) (22.23-22.48 mm) (22.99-23.24 mm) (23.75-24.00 mm) (24.51-24.77 mm) (25.27-25.53 mm) 3




Figure 1. PT Thrust Balance Air Supply Tubes 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 2. PT Thrust Balance Pressure Tap

d.

Start and operate gas turbine per Chapter 7 of GEK 105054, Volume I. Accelerate to obtain P5.4 pressure of 60 psia (413.7 kPa) or greater and stabilize. NOTE For a copy of NO.7B THRUST BALANCE ORIFICE SELECTION Excel spreadsheet, contact GE customer service.

e.

Record parameters required to calculate No. 7B thrust load. Input parameters into NO.7B TRUST BALANCE ORIFICE SELECTION Excel spreadsheet (figure 3) to verify orifice plate size.

f.

Shut down gas turbine per GEK 105054, Volume I, Chapter 7.




Figure 3. No.7B Thrust Balance Orifice Selection Worksheet (Example) 6 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



If necessary, replace orifice plate (3, figure 1) as follows: (1)

Remove self-locking nuts (1) and bolts (2) securing forward and aft sections of PT thrust balance air supply tubes (5 and 6) together.

(2)

Remove orifice plate (3) and square seal gaskets (4) from between forward and aft sections of PT thrust balance air supply tubes (5 and 6). NOTE

The replacement orifice plate must be installed correctly. The plate has an identification tab indicating forward and aft installation orientation. (3)

Install replacement orifice plate (3) and square seal gaskets (4) between forward and aft sections of PT thrust balance air supply tubes (5 and 6).

(4)

Lightly coat threads of four bolts (2) with thread lubricant.

(5)

Using bolts (2) and self-locking nuts (1), secure forward and aft sections of PT thrust balance air supply tube (5 and 6). Tighten nuts to 55-70 lb-in. (6.3-7.9 N⋅m) of torque.

h.

To determine if further adjustment is necessary, recheck PT thrust balance cavity pressure at the same P5.4 settings as used in step 6.e.

i.

Install cap (figure 2) on PT thrust balance cavity pressure tap, if used, as follows:

j.

(1)

Lightly coat cap threads with thread lubricant.

(2)

Install cap on PT thrust balance cavity pressure tap. Tighten cap to 180-200 lb in. (20.4-22.5 N⋅m) of torque.

Change alarm settings to comply with this work package. Proceed as follows: (1)

Make arrangements to collect and input the following parameters into the control system:

• P ambient (P0) in PSIA • Inlet pressure (P2) in PSIA • CDP pressure (PS3) in PSIA • No. 7B TBP Pressure (PABP) in PSIA • PT inlet pressure (P48 or P54) in PSIA • PT inlet temperature (T48 or T45) in degrees F • PT rotor speed (NPT) in RPM 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 431 00 (2)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Calculate No.7B bearing load using the following equation:

No.7B load=-7127+641*P48-381*PABP+27.3*SQRT(NPT/SQRT(T48+459.7))*P48-360*(P0-14.696)

(3)

If No.7B load calculated in step 2 is greater than 8500, set off HIGH LOAD ALARM. If No.7B load calculated in step 2 is less than 8500, set off LOW LOAD ALARM. NOTE

For a copy of NO.7B TRUST BALANCE ORIFICE SELECTION Excel spreadsheet, contact GE customer service. (4) In the event of an either HIGH LOAD ALARM or LOW LOAD ALARM, resize orifice plate according to NO.7B THRUST BALANCE ORIFICE SELECTION Excel spreadsheet (figure 3).




WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR/GAS TURBINE PRESERVATION, DEPRESERVATION, AND STORAGE MAINTENANCE (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Page

Definitions. .......................................................................................................................... 4 Depreservation of Engine. .................................................................................................. 14 Noninstalled Engine Preservation For Indefinite Period. ................................................ 6 Installed Engine Preservation For 30 Days or Less.......................................................... 4 Installed Engine Preservation When Engine Cannot Be Motored................................... 4 Noninstalled Engine Preservation For Indefinite Period. ................................................ 6 Noninstalled Engine Preservation For 30 Days or Less. .................................................. 6 Oil Wetting of Engine Bearings.......................................................................................... 8


GEK 105054 Volume II WP 500 00 1.


Introduction. This work package provides instructions for preserving and readying LM2500+ Models GK and GV gas generators and Model PK gas turbine. For LM2500+ Model PV gas turbine, preservation and depreservation instructions for the gas generator are per this work package. For LM2500+ Model PV gas turbine power turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title

For LM2500+ Models GK and GV gas generators, Model PK gas turbine, and Model PV gas turbine gas generator only: Operation and Maintenance Manual, Volume I GEK 105054 Installation/Initial Startup and Engine Operation Chapter 7 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Water Wash WP 405 00 Gas Generator/Gas Turbine Shipping WP 502 00 Shipping Container Inspection and Reconditioning WP 504 00 Illustrated Parts Breakdown GEK 105055 For LM2500+ Model PV gas turbine power turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


Part No.

Spline, Adapter, Manual or Aft Drive Pad Drive Motor, Electric (115 Vac) Drive Motor, Electric (220 Vac) Drive Motor, Electric (115 Vac/220 Vac) Stand, Portable Lubricating

1C8208G02 2C14764G01 2C14764G02 2C14764G05 Local Purchase






Barrier Paper Desiccant Lubricating Oil

MIL-B-121 MIL-D-3464 MIL-L-23699 or MIL-L-7808 GE Spec D50TF6 or Brayco 599 736L680G01 R297P04 (Alt)

Rust Preventative Concentrate Safety Cable Safety Wire 5.


IPB Figure No./Item

Preformed Packing Preformed Packing Preformed Packing Preformed Packing Preformed Packing

TBP TBP TBP 8-96 8-153


GEK 105054 Volume II WP 500 00 6.


Definitions. CAUTION ENGINE SHALL NOT BE STORED IN ANY MANNER THAT ALLOWS ROUTINE EXPOSURE TO OUTSIDE ELEMENTS.

7.

a.

Installed engine: An engine installed in the enclosure/package, with all service connections in place, capable of being started and run to idle level with no further connections required. The attached power turbine and/or accessories shall be capable of being rotated. The enclosure/package shall be weather-tight.

b.

Noninstalled engine: An engine installed in the enclosure/package, with partial or no service connections in place, incapable of being started without further maintenance. An engine installed in a maintenance dolly, or an engine installed in the shipping container, or any other condition not addressed by step a.

c.

Normal environment: Temperature 25 to 85°F (-4 to 29°C), relative humidity 25-65 percent.

Installed Engine Preservation For 30 Days or Less. a.

Comply with all instructions contained in WP 002 00. CAUTION ENSURE ATTACHED POWER TURBINE AND/OR ACCESSORIES ARE PRELUBRICATED OR DRIVE SHAFT IS DISCONNECTED PRIOR TO MOTORING ENGINE. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO POWER TURBINE AND/OR ACCESSORIES.

8.

b.

Water-wash engine per WP 405 00.

c.

Motor engine for minimum of 3 minutes per GEK 105054, Chapter 7.

d.

Using moisture barrier paper, cover inlet and exhaust openings. Cover or plug all engine openings and unattached fittings.

Installed Engine Preservation When Engine Cannot Be Motored (Repeat Every 60 Days or Less). a.

Comply with all instructions contained in WP 002 00. NOTE For preservation periods that are 60 days or more, use of rust preventative concentrate is mandatory.

b.

Water-wash engine per WP 405 00.





d.

Oil wet bearings per paragraph 12.

e.

At 30 day intervals: (1)

Remove moisture barrier paper, covers, and plugs installed on engine. CAUTION

9.

•

ENSURE ATTACHED POWER TURBINE AND/OR ACCESSORIES ARE PRELUBRICATED. FAILURE TO COMPLY MAY RESULT IN DAMAGE TO POWER TURBINE AND/OR ACCESSORIES.

•

DO NOT EXCEED STARTER DUTY CYCLE WHEN MOTORING.

•

HYDRAULIC STARTER HAS NO DUTY CYCLE LIMITATIONS, HOWEVER, OIL TEMPERATURE SHALL BE MAINTAINED BELOW 140°F (60°C).

•

PNEUMATIC STARTER DUTY CYCLE IS AS FOLLOWS: 5 MINUTES ON, 2 MINUTES OFF, 5 MINUTES ON, 18 MINUTES OFF OR 10 MINUTES ON, 20 MINUTES OFF.

(2)

Motor engine for minimum of 3 minutes per GEK 105054, Chapter 7.

(3)


Installed Engine Preservation For Indefinite Period. a.

Comply with all instructions contained in WP 002 00. CAUTION FOR PRESERVATION PERIODS THAT EXTEND PAST 60 DAYS, USE OF RUST PREVENTATIVE CONCENTRATE IS MANDATORY.

b.

Add 5 percent (by volume) of rust preventative concentrate to lubricating oil tank, if not previously added, per packager’s manual.

c.

Perform paragraph 8, steps b. through e.




10. Noninstalled Engine Preservation For 30 Days or Less. a.

Comply with all instructions contained in WP 002 00. NOTE Step b. applies only if engine is stored in a shipping container.

b.

If possible, shipping container shall be stored in shaded area, away from direct sunlight, and within limits of normal environment.

c.

Maintain and update engine storage log as required, or at a maximum interval of every 30 days. Information shall include: recorded humidity conditions, oil wetting dates, and desiccant replacement.

11. Noninstalled Engine Preservation For Indefinite Period. a.


b.

Maintain and update engine storage log as required, or at a maximum interval of every 30 days. Information shall include: recorded humidity conditions, oil wetting dates, and desiccant replacement.

c.

If engine is in shipping container, inspect container humidity indicator (figure 1) for color. Indicator shall appear blue, indicating safe humidity conditions. If indicator appears pink, proceed as follows: (1)

Remove shipping container cover per WP 502 00.

(2)

Replace desiccant per WP 502 00.

(3)

Reinstall shipping container cover per WP 502 00.

(4)

At next 30 day inspection, note humidity indicator appearance. If indicator is any color other than blue, proceed as follows: (a) Repeat substeps (1) and (2). (b) Inspect container cover seal per WP 504 00. Replace seal if required. (c) Oil wet bearings per paragraph 12. (d) Reinstall shipping container cover per WP 502 00.




Figure 1. Humidity Indicator - LM2500+ Shipping Container 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



12. Oil Wetting of Engine Bearings. a.


b.

Perform oil wetting of engine bearings as follows: (1)

Remove moisture barrier paper, covers, and plugs installed on engine. CAUTION

SHUT OFF MAIN LUBE SUPPLY LINE PRIOR TO DISCONNECTING IF DISCONNECTING FROM ENGINE LUBE AND SCAVENGE PUMP. (2)

Connect portable lubricating stand supply and scavenge pumps (figures 2 and 3) as follows: WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) If connected, disconnect lube supply hose from lube and scavenge pump inlet supply tube. Drain residual oil into appropriate container. (b) Connect portable lubricating stand supply line to lube and scavenge pump inlet supply tube. Tighten nut to 112-128 lb ft (151.9-173.5 N⋅m) of torque. (c) If connected, disconnect hose from lube and scavenge pump scavenge discharge tube. Drain residual oil into appropriate container. (d) Cap scavenge discharge tube. (e) Remove safety wire and remove drain plug from forward side of accessory gearbox. Discard preformed packing. (f) Install fitting into accessory gearbox drain hole. (g) Connect portable lubricating stand scavenge line to fitting in accessory gearbox drain hole. (h) For gas generators, remove safety wire and remove B- and C-sump scavenge screens from bottom of lube and scavenge pump. (i) For gas turbines, remove safety wire and remove B-, C-, and D-sump scavenge screens from bottom of lube and scavenge pump.




Figure 2. Typical Portable Lubricating Stand-Gas Generator 9 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. Typical Portable Lubricating Stand-Gas Turbine 10 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.


LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (j)

Install fittings into ports in lube and scavenge pump where sump screens have been removed.

(k) Connect portable lubricating stand scavenge lines to fittings in lube and scavenge pump sump ports. (3)

Install spline adapter and electric drive motor as follows: (a) Remove nuts and washers that secure aft drive pad cover onto accessory gearbox. Remove cover and discard preformed packing. WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (b) Using lubricating oil, lubricate spline adapter, 1C8208. (c) Using washers and nuts, secure spline adapter, 1C8208, into aft drive spline. Tighten nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque. (d) Install electric drive motor, 2C14764, onto aft drive pad. Align square drive of drive motor with spline adapter, 1C8208. (e) Using washers and bolts, secure drive motor to accessory gearbox aft drive pad. Tighten bolts to 420-510 lb in. (47.5-57.6 N⋅m) of torque. (f) Connect drive motor to applicable power source. (4)

Oil wet bearings as follows: NOTE

The use of rust preventative concentrate is optional if preservation period is less than 60 days. (a) Add 5 percent (by volume) of rust preventive concentrate to lubricating oil tank of portable lube stand.




ENSURE PORTABLE LUBRICATING STAND SCAVENGE LINES SHOW VISIBLE FLOW THROUGH VIEWING WINDOWS. IF FLOW IS NOT OBSERVED, STOP PORTABLE LUBRICATING STAND AND SCAVENGE PUMPS. CHECK ALL HOSES AND FITTINGS FOR LEAKS. FAILURE TO COMPLY WILL RESULT IN OVERFLOW OF ENGINE OIL SUMPS. (b) Start portable lubricating stand supply and scavenge pumps. Ensure supply pressure is regulated to 5-10 psi (34.5-68.9 kPa). Ensure lubricating oil supply oil temperature is 60 to 100°F (15.6 to 37.7°C). (c) Using drive motor, 2C14764, rotate high pressure compressor (HPC) rotor in forward direction for minimum of two rotations (12-15 minutes) at maximum RPM. If installed, rotate power turbine by hand using forward adapter. (d) Stop portable lubricating stand supply pump. (e) Run portable lubricating stand scavenge pump until no oil flow is visible in scavenge lines viewing windows. (f) Stop portable lubricating stand scavenge pump. (5)

Disconnect portable lubricating stand supply and scavenge pumps as follows: WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (a) Remove portable lubricating stand scavenge lines from sump port fittings in lube and scavenge pump and accessory gearbox drain fitting. Drain residual oil into appropriate container. (b) Using lubricating oil, lubricate new preformed packings for sump screens and accessory gearbox drain plug. (c) Install preformed packing onto sump screens and accessory gearbox drain plug. (d) Install drain plug into accessory gearbox. Tighten drain plug to 270-300 lb in. (30.6-33.9 N⋅m) of torque and safety wire. (e) For gas generators, install B- and C-sump inlet screens into lube and scavenge pump sump ports. Tighten screens to 55-70 lb in. (6.3-7.9 N⋅m) of torque and safety wire.




(f) For gas turbines, install B-, C-, and D-sump inlet screens into lube and scavenge pump port. Tighten screens to 55-70 lb in. (6.3-7.9 N⋅m) of torque and safety wire. (g) Remove cap from lube and scavenge pump scavenge discharge tube. (h) Connect hose to lube and scavenge pump scavenge discharge tube, if applicable. Tighten nut to 112-128 lb ft (151.9-173.5 N⋅m) of torque. (i) Disconnect portable lubricating pump supply line from lube and scavenge pump inlet. Drain residual oil into appropriate container. (j)

Connect hose to lube and scavenge pump inlet supply tube, if applicable. Tighten nut to 112-128 lb ft (151.9-173.5 N⋅m) of torque.

(k) If applicable, open lube tank supply line per packager’s manual. (6)

Remove spline adapter and electric/pneumatic drive motor as follows: (a) Remove bolts and washers that secure electric drive motor, 2C14764, onto aft drive pad of accessory gearbox. Remove drive motor. (b) Remove nuts and washers that secure spline adapter, 1C8208, into aft drive spline of accessory gearbox. Remove spline adapter. WARNING

LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA. (c) Using lubricating oil, lubricate preformed packing. (d) Install preformed packing into groove on aft drive pad cover. (e) Install aft drive pad cover onto accessory gearbox. Secure using washers and nuts. Tighten nuts to 100-130 lb in. (11.3-14.6 N⋅m) of torque. (7)





13. Depreservation of Engine. a.


b.

If applicable, depreserve lubricating oil supply as follows: WARNING LUBRICATING OIL, MIL-L-23699 OR MIL-L-7808, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

c.

d.

(1)

Drain engine lubricating tank oil per packager’s manual.

(2)

Remove safety wire and remove drain plug from forward side of accessory gearbox. Discard preformed packing.

(3)

Drain lubricating oil into suitable container.

(4)

Using lubricating oil, lubricate preformed packing.

(5)

Install preformed packing onto drain plug.

(6)

Install drain plug into accessory gearbox. Tighten drain plug to 270-300 lb in. (30.6-33.9 N⋅m) of torque and safety wire.

(7)

Refill engine lubricating tank oil per packager’s manual.

For noninstalled engines: (1)

Remove engine from shipping container per WP 502 00, if applicable.

(2)

Install engine per WP 300 00 or WP 301 00, if applicable.

(3)

Perform paragraph 11, step b.

(4)

Install and start engine per GEK 105054, Chapter 7.

For installed engines: (1)

Remove desiccant from enclosure/package.

(2)

Perform paragraph 11, step b.

(3)

Install and start engine per GEK 105054, Chapter 7.




WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE PRESERVATION, DEPRESERVATION, AND STORAGE MAINTENANCE (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Definitions. .......................................................................................................................... Depreservation of Power Turbine....................................................................................... Installed Power Turbine Preservation For Indefinite Period. .......................................... Installed Power Turbine Preservation For 30 Days or Less. ............................................ Installed Power Turbine Preservation For 60 Days or Less. ............................................ Noninstalled Power Turbine Preservation For 30 Days or Less. .....................................

3 4 3 3 3 3


GEK 105054 Volume II WP 501 00 1.


Introduction. This work package provides instructions for the preservation, storage, and depreservation of the LM2500+ Model PK gas turbine power turbine. For LM2500+ Model GV gas generator and Model PV gas turbine power turbine, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title

For the LM2500+ Model PK gas turbine power turbine: Operation and Maintenance Manual, Volume I GEK 105054 Installation/Initial Startup and Engine Operation Chapter 7 Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Gas Generator Assembly Replacement WP 301 00 Power Turbine Assembly Replacement WP 302 00 Gas Generator-Gas/Turbine Preservation, Depreservation, and Storage Maintenance WP 500 00 Power Turbine Shipping WP 503 00 Shipping Container Inspection and Reconditioning WP 504 00 For LM2500+ Model GV gas generator and Model PV gas turbine power turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.


4.


5.

Nomenclature


Desiccant Lubricating Oil

MIL-P-3464 MIL-L-23699 or MIL-L-7808





Definitions. CAUTION ENGINE OR POWER TURBINE SHALL NOT BE STORED IN ANY MANNER THAT ALLOWS ROUTINE EXPOSURE TO OUTSIDE ELEMENTS.

7.

a.

Installed power turbine: A power turbine installed in the enclosure/package, attached to a gas generator, thereby forming a gas turbine assembly. The engine shall be capable of being started and run to idle level with no further connections required. The attached power turbine and/or accessories shall be capable of being rotated. The enclosure/package shall be weather-tight.

b.

Noninstalled power turbine: A power turbine installed in the enclosure/package, with partial or no service connections in place, incapable of being rotated without further maintenance; or a power turbine installed in the shipping container.

Installed Power Turbine Preservation For 30 Days or Less. a.

8.

Installed Power Turbine Preservation For 60 Days or Less. a.

9.

Refer to WP 500 00.

Refer to WP 500 00.

Installed Power Turbine Preservation For Indefinite Period. a.

Refer to WP 500 00.

10. Noninstalled Power Turbine Preservation For 30 Days or Less. a.

If possible, shipping container shall be stored in shaded area, away from direct sunlight, and within limits of normal environment.

b.

Maintain and update power turbine storage log as required, or at a maximum interval of every 30 days. Information shall include: recorded humidity conditions and desiccant replacement.

c.

Every 30 days, inspect container humidity indicator for color. Indicator shall appear blue, indicating safe humidity conditions. If indicator appears pink, proceed as follows: (1)

Remove shipping container cover per WP 503 00.

(2)

Replace desiccant.

(3)

Reinstall shipping container cover per WP 503 00.


GEK 105054 Volume II WP 501 00 (4)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines At next 30 day inspection, note humidity indicator appearance. If indicator is any color other than blue, proceed as follows: (a) Repeat substeps (1) and (2). (b) Inspect container cover seal per WP 504 00. Replace seal if required. (c) Reinstall shipping container cover per WP 503 00.

11. Depreservation of Power Turbine. a.


b.

If applicable, depreserve lubricating oil supply as follows: WARNING LUBRICATING OIL, MIL-L-23699, IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. USE IN A WELL-VENTILATED AREA.

c.

d.

(1)

Drain lubricating tank oil per packager’s manual.

(2)

Prepare gas generator per WP 500 00.

(3)

Refill lubricating tank oil per packager’s manual.

For noninstalled power turbines: (1)

Remove power turbine from shipping container per WP 503 00, if applicable.

(2)

Install power turbine assembly per WP 302 00, if applicable.

(3)

Install gas generator assembly per WP 301 00, if applicable.

(4)

Oil wet gas turbine bearings per paragraph 12, step b.(4) of WP 500 00.

(5)

Start gas turbine per GEK 105054, Chapter 7.

For installed power turbines: (1)

Remove desiccant from enclosure/package, if installed.

(2)

Oil wet gas turbine bearings per paragraph 12, step b.(4) of WP 500 00.

(3)

Start gas turbine per GEK 105054, Chapter 7.




WORK PACKAGE

TECHNICAL PROCEDURES GAS GENERATOR/GAS TURBINE SHIPPING (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Page

Configuration of Inner Frame. ........................................................................................... 17 Engine Installation Into Shipping Container. ................................................................... 17 Engine Removal From Shipping Container. ...................................................................... 3


1

GEK 105054 Volume II WP 502 00 1.


Introduction. This work package provides instructions for installing and removing LM2500+ Model GK gas generator and Model PK gas turbine from the LM2500 universal shipping container. For LM2500+ Model GV gas generator and Model PV gas turbines, shipping and handling instructions of the gas generator are per this work package, with shipping and handling of the two stage power turbine provided in GEK 105052, Operation and Maintenance Manual. In addition this work package covers configuring the LM2500 universal shipping container for shipment of either a gas generator or gas turbine.

2.


Title

For LM2500+ Model GK gas generator and Model PK gas turbine: Operation and Maintenance Manual, Volume II GEK 105054 Gas Turbine Assembly Replacement WP 300 00 Gas Generator Assembly Replacement WP 301 00 Maintenance Dolly Usage WP 303 00 Shipping Container Inspection and Reconditioning WP 504 00 For LM2500+ Model GV gas generator and Model PV gas turbine: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

4.

5.

2


Part No.

Set, Lift Attachment Fixture, Lifting-Gas Generator Fixture, Lifting-Gas Turbine Container, Shipping-LM2500 Universal Lift, Quad Link (6,000 lb [2721 kg] minimum rating) Sling, Nylon (4,000 lb [1814 kg] minimum rating)

1C8017G01 1C8340G01 1C8341G01 106C7156P02 Local Purchase Local Purchase



Desiccant

MIL-P-3464





Engine Removal From Shipping Container. a.

If desired, move shipping container to enclosure, using hoist and lift attachment set, 1C8017. Refer to table 1 for weights and dimensions of shipping container, gas generator, gas turbine, and power turbine. Table 1. Shipping Weights and Dimensions

Item

Weight

Length

Width

Height

Gas Generator/ Gas Turbine Container

12,000 lb (5,443 kg)

220.00 in. (5,588.0 mm)

101.50 in. (2,578.1 mm)

99.25 in. (2,521.0 mm)

Power Turbine Container

2,700 lb (1,225 kg)

-

-

-

Gas Turbine and Container

20,181 lb (9,154 kg)

-

-

-

Gas Turbine

8,181 lb (3,711 kg) without fuel system

214.725 in. (5,454.02 mm)

-

-

Power Turbine

2,830 lb (1,284 kg)

58.8 in. (1,494 mm)

-

-

Gas Generator

4,735 lb (2,148 kg) without fuel system

161.23 in. (4,095.2 mm)

-

-

Gas Turbine (L50101)

8,104 lb (3,676 kg) with forward adapter

191.248 in. (4,857.70 mm)

-

-

Power Turbine (L50101)

3,314 lb (1,503 kg)

-

-

-

Gas Generator (L50101)

4,590 lb (2,082 kg)

137.753 in. (3,498.93 mm)

-

-

Forward Adapter

100 lb (45 kg)

-

-

-


3



Prepare shipping container as follows: (1)

Depressurize shipping container by depressing button located in center of pressure relief valve (figure 1).

(2)

Loosen nuts on T-bolts that secure shipping container cover to base.

(3)

Rotate T-bolts so boltheads drop into lower flange recess.

(4)

Using quad link lift, attach hoist to lift rings on shipping container cover (Detail A).

(5)

Attach nylon control lines onto shipping container cover. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE THAT ALL FASTENERS ARE IN UNLOCKED POSITION BEFORE LIFTING TOP SECTION OF CONTAINER OR DAMAGE TO CONTAINER AND ENGINE MAY OCCUR. (6)

Using hoist, lift shipping container cover straight up until clear of engine.

(7)

Using nylon control lines and hoist, move shipping container cover clear of engine and shipping container base.

(8)

Lower shipping container cover onto wooden support skids. Remove hoist. Leave quad link lift installed, if desired.

(9)

Lower four shipping container corner alignment posts. NOTE

Remove gas generator per step e. Remove gas turbine per step f. c.

Remove gas generator from shipping container as follows: (1)

4

Attach hoist rated for 10,000 lb (4536 kg) minimum onto lift fixture, 1C8340.




Figure 1. LM2500 Universal Shipping Container, 106C7156P02 (Sheet 1 of 2) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

5



Figure 1. LM2500 Universal Shipping Container, 106C7156P02 (Sheet 2 of 2) 6




ESTABLISH AND RECORD CENTER OF GRAVITY OF LIFT FIXTURE TO PREVENT FIXTURE PITCHING UPON REMOVAL FROM GAS GENERATOR. (2)

Remove the top 4 fuel feed tubes to give access to the CRF forward flange bolts and nuts.

(3)

Install lift fixture, 1C8340, aft bracket (figure 2) onto gas generator as follows: CAUTION

SET ASIDE GAS GENERATOR HARDWARE FOR REUSE. DO NOT INTERMIX FIXTURE HARDWARE WITH GAS GENERATOR HARDWARE. (a) Remove bolt and self-locking nut at 12:00 o’clock position of compressor rear frame (CRF) forward flange. (b) Remove seven bolts and self-locking nuts to either side of removed bolt and nut. (c) Install lift fixture, 1C8340, aft bracket onto aft side of CRF forward flange. (d) Using fifteen 0.3125-18 bolts and nuts, attach lift fixture aft bracket onto CRF forward flange. Tighten bolts to 70-110 lb in. (8.0-12.4 N⋅m) of torque. (4)


(5)


(6)


(7)

Using two quick-release pins, attach lift fixture forward links to gas generator forward handling mounts on compressor front frame (CFF).

(8)

Using two quick-release pins, attach lift fixture aft links to lift fixture aft bracket previously installed on gas generator above.

(9)

Remove forward yoke (figure 3) of shipping container from gas generator as follows: (a) Using lift fixture, 1C8340, and hoist, take up weight of gas generator so that shipping container forward yoke mounting pins can be removed from CFF.


7



Figure 2. Gas Generator Lift Fixture, 1C8340 (Sheet 1 of 2) 8




Figure 2. Gas Generator Lift Fixture, 1C8340 (Sheet 2 of 2) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

9



Figure 3. Shipping Container Inner Frame-Gas Generator Configuration 10




(b) Remove cotter pins and special flat washers from forward yoke mounting pins. (c) Remove forward yoke mounting pins from CFF. (d) Using nylon sling, attach hoist to forward yoke. (e) Remove eight bolts, washers, and nuts used to secure forward yoke to inner cradle mounting pads. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE FORWARD YOKE IS PROPERLY SECURED OR LAID DOWN, OR DAMAGE DUE TO FALLING MAY OCCUR. (f) Lift forward yoke and place away from shipping container. (10) Remove aft strongback of shipping container from gas generator as follows: (a) Remove 46 bolts, nuts, and washers that secure aft strongback to turbine mid frame (TMF) aft flange. (b) Using nylon sling, attach hoist to aft strongback. (c) Remove eight bolts, washers, and nuts used to secure aft strongback to inner cradle mounting pads. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE AFT STRONGBACK IS PROPERLY SECURED OR LAID DOWN, OR DAMAGE DUE TO FALLING MAY OCCUR. (d) Lift aft strongback and place away from shipping container.


11



USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (11) Using hoist and lift fixture, 1C8340, lift gas generator from shipping container. NOTE Gas generator can be either installed into maintenance dolly, 1C9372, for moving to enclosure or directly into enclosure. (12) Install gas generator into maintenance dolly, 1C9372, per WP 303 00 or into enclosure per WP 301 00. d.

Remove gas turbine from shipping container as follows: (1)

Attach hoist rated for 14,000 lb (6350 kg) minimum onto lift fixture, 1C8341.

(2)

Install lift fixture, 1C8341 (figure 4), onto gas turbine as follows: NOTE

Use of lift fixture, 1C8341, is dependent on space within enclosure. If space is not sufficient to allow use of lift fixture, 1C8341, attach packager’s lift fixture per packager’s manual. (a) Ensure forward lifting plate is installed in PLUS lifting position on lift fixture, 1C8341. (b) Attach hoist onto lift fixture, 1C8341, hoist attachment points. (c) Raise lift fixture, 1C8341, and align over gas turbine. (d) Using two quick-release pins, attach lift fixture forward links to gas turbine forward handling mounts on CFF. (e) Using two quick-release pins, attach lift fixture aft links to gas turbine ground handling mounts on TRF.

12




Figure 4. Gas Turbine Lift Fixture, 1C8341 Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

13

GEK 105054 Volume II WP 502 00 (3)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Remove forward yoke (figure 5) of shipping container from gas turbine as follows: (a) Using lift fixture, 1C8341, and hoist, take up weight of gas turbine so that shipping container forward yoke mounting pins can be removed from CFF. (b) Remove cotter pins and special flat washers and remove forward yoke mounting pins from CFF. (c) Using nylon sling, attach hoist to forward yoke. (d) Remove eight bolts, washers, and nuts used to secure forward yoke to inner cradle mounting pads. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE FORWARD YOKE IS PROPERLY SECURED OR LAID DOWN, OR DAMAGE DUE TO FALLING MAY OCCUR. (e) Lift forward yoke and place away from shipping container. (4)

Remove aft strongback of shipping container from gas turbine as follows: (a) Remove 46 bolts, nuts, and washers that secure aft strongback to turbine rear frame (TRF) aft flange. (b) Using nylon sling, attach hoist to aft strongback. (c) Remove eight bolts, washers, and nuts used to secure to inner cradle mounting pads.

14




Figure 5. Shipping Container Inner Frame-Gas Turbine Configuration Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

15



USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE AFT STRONGBACK IS PROPERLY SECURED OR LAID DOWN, OR DAMAGE DUE TO FALLING MAY OCCUR. (d) Lift aft strongback and place away from shipping container. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (5)

Using hoist and lift fixture, 1C8341, lift gas turbine from shipping container. NOTE

Gas turbine can be either installed into maintenance dolly, 1C9372, for moving to enclosure or directly into enclosure. (6)

16

Install gas turbine into maintenance dolly, 1C9372, per WP 303 00, or into enclosure per WP 300 00.

e.

Remove engine log book from shipping container receptacle.

f.

If required, install shipping container cover onto base as follows: (1)

Install 80-90 lb (36.3-40.8 kg) of desiccant and shipping container hardware into proper receptacles of shipping container.

(2)

Using low power heat gun, renew humidity indicator, if necessary.

(3)

Using quad link lift, attach 4000 lb (1814 kg) hoist to lift rings on shipping container cover (figure 1, detail A).




WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY. CAUTION BEFORE LOWERING UPPER CONTAINER HALF, ALIGN ALL T-BOLTS IN SLOTS, TO PREVENT COCKING OF LID AND POSSIBLE DAMAGE TO FLANGE GASKET.

7.

(4)

Raise four shipping container corner alignment posts.

(5)

Carefully lift top section of container straight up.

(6)

Using nylon control lines, align top cover with base section and lower.

(7)

Push all T-bolt fasteners up and through slots of upper container and turn 90 degrees (across slots). Hold T-boltheads in position (across slots) with suitable wrench or pliers. Tighten nuts to 35-42 lb ft (47.5-56.9 N⋅m) of torque.

Configuration of Inner Frame. a.

Inspect shipping container per WP 504 00. NOTE Universal shipping container, 106C7156, requires configuring the inner frame for mounting different engines. If same style engine is to be installed into shipping container as was removed, proceed to paragraph 8.

b. 8.

Configure inner frame for gas generator or gas turbine installation per placard located on shipping container.

Engine Installation Into Shipping Container. NOTE Prior to installation of the engine into the shipping container, the fuel system must be drained and purged according to the procedure in WP 300 00 or WP 301 00. a.

If desired, move shipping container to enclosure using hoist and lift attachment set, 1C8017. Refer to table 1 for weights and dimensions of shipping container, gas generator, gas turbine, and power turbine.

b.

If required, prepare shipping container per paragraph 6. step b.

c.

If not previously accomplished, inspect shipping container per WP 504 00. Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

17



Install gas generator per step d. Install gas turbine per step e. d.

Install gas generator into shipping container as follows: WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (1)

Using nylon sling and hoist, lift aft strongback and align with proper shipping container inner frame mounting holes. Ensure TMF mounting holes face forward.

(2)

Using eight bolts, nuts, and washers provided, secure aft strongback to inner frame. Tighten nuts to 82-95 lb ft (111.2-128.8 N⋅m) of torque. NOTE

Gas generator can be installed directly into shipping container from enclosure, if desired. (3)

If necessary, prepare maintenance dolly for gas generator removal per WP 303 00. WARNING


18

(4)

Using hoist and lift fixture, 1C8340, lift gas generator.

(5)

Align gas generator TMF with shipping container aft strongback.

(6)

Position TMF aft flange against forward flange of shipping container aft strongback.

(7)

Using 46 bolts, nuts, and washers, secure gas generator TMF to aft strongback. Install boltheads facing forward with washers next to nuts. Tighten bolts to 13-18 lb ft (17.6-24.4 N⋅m) of torque.

(8)

Using nylon sling and hoist, lift forward yoke.

(9)

Carefully position forward yoke over CFF.



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (10) Lower forward yoke onto CFF.

(11) Align gas generator CFF mounting brackets with forward yoke mounting holes. (12) Using forward yoke mounting pins and special flat washers, secure gas generator CFF to forward yoke. Slide cotter pins through mounting pins. (13) Using eight bolts, nuts, and washers, secure forward yoke to shipping container inner frame. Tighten bolts to 82-95 lb ft (111.2-128.8 N⋅m) of torque. (14) Remove lift fixture, 1C8340 (figure 2), from gas generator as follows: (a) Using two quick-release pins, attach lift fixture forward links to gas generator forward handling mounts on CFF. (b) Using two quick-release pins, attach lift fixture aft links to aft bracket installed on gas generator. (c) Remove 15 bolts and self-locking nuts that secure CRF forward flange to lift fixture, 1C8340, aft bracket. (d) Remove lift fixture, 1C8340, aft bracket from CRF forward flange. CAUTION INSTALL PRIME GAS GENERATOR HARDWARE. DO NOT INTERMIX FIXTURE HARDWARE WITH GAS GENERATOR HARDWARE. (e) Install 15 prime bolts and nuts though compressor case rear flange. Install three longer bolts in boltholes used to secure sump support bracket. Tighten bolts to 209-231 lb. in. (23.6-26.0 N⋅m) of torque. (f) Reinstall top 4 fuel feed tubes (if removed). e.

Install gas turbine into shipping container as follows: WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (1)

Using nylon sling and hoist, lift aft strongback and align with proper shipping container inner frame mounting holes. Ensure TMF mounting holes face forward.


19

GEK 105054 Volume II WP 502 00 (2)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Using eight bolts, nuts, and washers provided, secure aft strongback to inner frame. Tighten nuts to 82-95 lb ft (111.2-128.8 N⋅m) of torque. NOTE

Gas turbine can be installed directly into shipping container from enclosure if desired. (3)

If necessary, prepare maintenance dolly for gas turbine removal per WP 303 00. WARNING


Using hoist and lift fixture, 1C8341, lift gas turbine.

(5)

Align gas turbine TRF with shipping container aft strongback.

(6)

Position TRF aft flange against forward flange of shipping container aft strongback.

(7)

Using 46 bolts, nuts, and washers, secure gas turbine TRF to aft strongback. Install boltheads facing forward with washers next to nuts. Tighten bolts to 13-18 lb ft (17.6-24.4 N⋅m) of torque.

(8)

Using nylon sling and hoist, lift forward yoke.

(9)

Carefully position forward yoke over CFF.

(10) Lower forward yoke onto CFF. (11) Align gas turbine CFF mounting brackets with forward yoke mounting holes. (12) Using forward yoke mounting pins and special flat washers, secure gas generator CFF to forward yoke. Slide cotter pins through mounting pins. (13) Using eight bolts, nuts and washers, secure forward yoke to shipping container inner frame. Tighten bolts to 82-95 lb ft (111.2-128.8 N⋅m) of torque.

20



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines CAUTION DO NOT OVERTIGHTEN SELF-LOCKING NUTS ON CLEVISES, OR DAMAGE TO ENGINE SHALL OCCUR. (14) Remove lift fixture, 1C8341, from gas turbine as follows:

(a) Remove two quick-release pins that attach lift fixture forward links to gas turbine forward handling mounts on CFF. (b) Remove two quick-release pins that attach lift fixture aft links to gas turbine aft handling mounts on TRF. (c) Using enclosure hoist, raise lift fixture, 1C8341, away from gas turbine. f.

Install cover onto shipping container per paragraph 6., step h.

g.

Install logbook into shipping container receptacle.

Change 1

21/(22 Blank)





TECHNICAL PROCEDURES AIR RIDE KIT INSTALLATION (LEVEL 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.

1 - 10.................. 1


Page

Air Ride Kit Installation. .................................................................................................... Air Ride Kit Removal. .........................................................................................................

3 8


1



Introduction.

This work package provides instructions for installing and removing the LM2500 gas turbine shipping container air ride kit. The air ride kit is designed to reduce the possibility of bearing damage in gas generators and gas turbines installed in shipping containers, in areas where trucks and trailers with air ride suspensions may not be available. The air ride kit is made up of two box assemblies. Each assembly is made up of two interconnected air ride boxes. During shipping, one air ride box assembly is attached to each end of the gas turbine shipping container. Each air ride box assembly weighs approximately 850 pounds (386 kg). 2.

Reference Material. None required.

3.

Support Equipment Required.

4.

Nomenclature

Part No.

Kit, Air Ride Container, Shipping-LM2500 Universal

00202050000 106C7156P02


Specification

Compressed air 5.

2





Air Ride Kit Installation. NOTE

•

Air ride kit can only be installed on containers that have a dark blue painted base (bottom section of container).

•

Two interconnected air ride boxes make up each air ride box assembly.

a.

Open air pressure release valve (9, figure 1), two valves inside each of the four air ride boxes (1 and 15), to release any residual air pressure present in the air bags.

b.

Remove bolts (5) that secure air ride box lids (2) to boxes. Open box lids. WARNING ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR DEATH. CAUTION YELLOW LIFTING BARS ON AIR RIDE BOXES ARE FOR INSTALLATION OR REMOVAL OF AIR RIDE BOXES ONLY. DO NOT ATTEMPT TO LIFT GAS TURBINE SHIPPING CONTAINER USING AIR RIDE BOX LIFTING BARS, OR DAMAGE TO AIR RIDE BOX, SHIPPING CONTAINER, OR GAS TURBINE MAY RESULT.

c.

Using forklift, or overhead hoist with a minimum 1000-pound (454 kg) capacity connected to yellow lifting bars (4), move left side air ride box (1) into position at end of gas turbine shipping container (11). Align boltholes in air ride box to boltholes in gas turbine shipping container. NOTE Do not fully tighten bolts until both air ride boxes and connecting channel have been installed with all bolts hand-tight.

d.

Secure left side air box (1) to gas turbine shipping container with 12 bolts (3). Tighten bolts hand-tight.

e.

Repeat steps 6.c. and 6.d. to install right side air box (15) to gas turbine shipping container.

f.

Install connecting channel (13) to air ride boxes (1 and 15), aligning boltholes in connecting channel with boltholes in air ride boxes. Secure connecting channel to each air ride box with four bolts (12). Tighten bolts hand-tight.

g.

Tighten bolts (3) to 69-81 lb ft (94-109 N·m) of torque.

h.

Tighten bolts (12) to 69-81 lb ft (94-109 N·m) of torque.

i.

Repeat steps 6.c. through 6.h. to install second air ride box assembly to other end of gas turbine shipping container. Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

3



Figure 1. Air Ride Kit (Sheet 1 of 3) 4




Figure 1. Air Ride Kit (Sheet 2 of 3) Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

5



Figure 1. Air Ride Kit (Sheet 3 of 3) 6



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines j.

Verify, and adjust as necessary, that adjustable shock dampers (14, figure 1) are set to the No. 6 setting.

k.

Close lids on the four air ride boxes and secure each lid with two bolts (5). Tighten bolts to 69-81 lb ft (94-109 N·m) of torque.

l.

Open the two air shutoff valves (6) inside each of the four air ride boxes. WARNING SERIOUS INJURY CAN OCCUR WHEN APPLYING PNEUMATIC PRESSURE. EYE PROTECTION IS REQUIRED. RELIEVE PRESSURE BEFORE DISCONNECTING LINES AND FITTINGS.

m. Using compressed air and air pressure gauges (7), apply air to air inlet valves (8) to inflate air bags to 40-50 psig (276-344 kPa gage). NOTE If gas turbine shipping container is to be transported empty, it is acceptable, but not a requirement, to pressurize air bags. n.

After air bags are pressurized to the correct air pressure setting, remove compressed air source and close the two air shutoff valves (6) inside each of the four air ride boxes. WARNING ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR DEATH. CAUTION YELLOW LIFTING BARS ON AIR RIDE BOXES ARE FOR INSTALLATION OR REMOVAL OF AIR RIDE BOXES ONLY. DO NOT ATTEMPT TO LIFT GAS TURBINE SHIPPING CONTAINER USING AIR RIDE BOX LIFTING BARS, OR DAMAGE TO AIR RIDE BOX, SHIPPING CONTAINER, OR GAS TURBINE MAY RESULT. NOTE If gas turbine shipping container is lifted with a forklift or overhead crane or hoist, air ride box assemblies may sag off ends of shipping container. This is acceptable and will not damage the air ride box assemblies or container.

o.

Using forklift, or overhead crane or hoist, install gas turbine shipping container on truck trailer bed.


7



DURING TRANSPORT OF GAS TURBINE, MAKE SURE SHIPPING CONTAINER IS NOT DIRECTLY CHAINED TO OR IN DIRECT CONTACT WITH TRAILER BED, OR DAMAGE TO GAS TURBINE BEARINGS MAY RESULT.

7.

p.

Secure air ride boxes on each corner of gas turbine shipping container to truck trailer bed, using chains between trailer and tie down rings (10) on air ride box (figure 2). Make sure clearance between gas turbine shipping container (11) and bed of truck is between 2-3 inches (51-76 mm). Gas turbine shipping container must not be chained to or in direct contact with trailer bed.

q.

If clearance between gas turbine shipping container (11) and bed of truck is not between 2-3 inches (51-76 mm), remove tie-down chains and verify air ride box inflation pressure of 40-50 psig (276-344 kPa gage).

Air Ride Kit Removal. WARNING ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR DEATH. CAUTION YELLOW LIFTING BARS ON AIR RIDE BOXES ARE FOR INSTALLATION OR REMOVAL OF AIR RIDE BOXES ONLY. DO NOT ATTEMPT TO LIFT GAS TURBINE SHIPPING CONTAINER USING AIR RIDE BOX LIFTING BARS, OR DAMAGE TO AIR RIDE BOX, SHIPPING CONTAINER, OR GAS TURBINE MAY RESULT. NOTE If gas turbine shipping container is lifted with a forklift or overhead crane, air ride kits may sag off ends of shipping container. This is acceptable and will not damage the kits or container.

8

a.

If necessary, using forklift or overhead crane or hoist, remove gas turbine shipping container from truck trailer bed and place on shop floor or other suitable surface.

b.

Open the two air shutoff valves (6, figure 1) inside each of the four air ride boxes (1 and 15).

c.

Open two air pressure release valves (9) inside each of the four air ride boxes, to release air pressure present in the air bag.

d.

Remove bolts (12) that secure connecting channel (13) to left and right air ride boxes (1 and 15). Remove connecting channel.




Figure 2. Tie-Down of Air Ride Box to Truck Trailer Bed Change 1 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

9


10


e.

Remove bolts (5) that secure air ride box lids (2) to air ride boxes. Open box lids.

f.

Remove bolts (3) that secure air ride boxes to gas turbine shipping container (11).

g.

Using forklift, or overhead hoist with a minimum 1000-pound (454 kg) capacity connected to yellow lifting bars (4), remove each air ride box from gas turbine shipping container (11).




WORK PACKAGE

TECHNICAL PROCEDURES POWER TURBINE SHIPPING (LEVEL 1 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODEL PK


Change No.

Page No.

Change No.

Page No.

Change No.


Page

Power Turbine Installation into Shipping Container. ...................................................... 11 Power Turbine Removal from Shipping Container. .......................................................... 3


GEK 105054 Volume II WP 503 00 1.


Introduction. This work package provides instructions for installing and removing LM2500+ Model PK gas turbine power turbine into a shipping container. For Model GV gas generator and Model PV gas turbine power turbines, refer to GEK 105052, Operation and Maintenance Manual, and GEK 105053, Illustrated Parts Breakdown.

2.


Title

For LM2500+ Model PK gas turbine power turbine: Operation and Maintenance Manual, Volume II GEK 105054 General Maintenance Practices WP 002 00 Power Turbine Forward Adapter Replacement WP 220 00 Power Turbine Assembly Replacement WP 302 00 Maintenance Dolly Usage WP 303 00 Shipping Container Inspection and Reconditioning WP 504 00 For LM2500+ Model GV gas generator and Model PV gas turbine power turbines: Operation and Maintenance Manual GEK 105052 Illustrated Parts Breakdown GEK 105053 3.

4.

5.


Part No.

Fixture, Lifting-Power Turbine Mount Set, Ground Handling-Power Turbine Fixture, Aft Lift and Turn-Power Turbine Frame Assembly, Maintenance Dolly Container, Shipping-Power Turbine Lift, Quad Link (6,000 lb [2,721 kg] minimum rating) Sling, Nylon (4,000 lb [1,814 kg] minimum rating) Gun, Heat

1C6955G03 1C8321G01 1C8342G01 1C9372G04 106C7157P01 Local Purchase Local Purchase Local Purchase



Desiccant Thread Lubricant

MIL-P-3464 GE Spec A50TF201





Power Turbine Removal from Shipping Container. a.

Comply with all instructions contained in WP 002 00. NOTE Shipping container with power turbine installed weighs approximately 5,800 lbs (2,630 kg).

b.

If desired, move shipping container, 106C7157, to enclosure per one of following methods: (1)

Using hoist and sling, proceed as follows: (a) Attach quad link lift to four lifteyes on shipping container lid. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (b) Using hoist attached to quad link lift, lift and move shipping container and power turbine to enclosure site. (2)

Using forklift, proceed as follows: (a) Align lift forks with guide tubes in base of shipping container. (b) Lift and move shipping container to enclosure site.

c.

Prepare shipping container as follows: (1)

Depressurize shipping container by depressing button located in center of pressure relief valve (figure 1).

(2)

Loosen nuts on 40 T-bolts that secure shipping container cover to base.

(3)

Rotate T-bolts so boltheads drop into lower flange recess.

(4)

Using quad link lift, attach hoist to lift rings on shipping container cover. Attach nylon control lines onto shipping container lift rings.




Figure 1. Power Turbine Shipping Container (Sheet 1 of 3) 4 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.








LM2500+ SAC GE Industrial AeroDerivative Gas Turbines WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. CAUTION ENSURE THAT ALL FASTENERS ARE IN UNLOCKED POSITION BEFORE LIFTING CONTAINER COVER, OR SHIPPING CONTAINER SHALL BE DAMAGED. (5)

Using hoist, lift shipping container cover straight up until clear of power turbine.

(6)

Using nylon control lines and hoist, move shipping container cover clear of power turbine and shipping container base.

(7)

Lower shipping container cover onto wooden support skids. Remove hoist. Leave quad link lift installed, if desired.

(8)

Lower four shipping container corner alignment posts. NOTE

d.

•

There are two methods for removal of power turbine from shipping container. For use of lift fixture, 1C6955, refer to step (1). For use of aft lift and turn fixture, 1C8342, and shipping container forward strongback, refer to step (2).

•


•

Aft lift and turn fixture, 1C8342, cannot be used when installing power turbine into enclosure.

Remove power turbine from shipping container as follows: (1)

Install lift fixture, 1C6955, onto power turbine as follows: (a) Install power turbine ground handling mount fixtures, 1C8321, onto power turbine as follows: CAUTION

DO NOT TURN BODY-BOUND BOLTS DURING REMOVAL, OR DAMAGE TO POWER TURBINE STATOR CASING MAY OCCUR. 1

Remove nine bolts, in boltholes 1 through 9, on horizontal split flange of power turbine stator case. Retain engine hardware for reinstallation.




Ground handling mount fixtures, 1C8321, are marked as to which side of power turbine they are to be installed on. Ensure fixtures are installed onto lower side of horizontal split line flange. 2

Using slave hardware, attach ground handling mount fixture, 1C8321, onto power turbine. Tighten bolts to 70-110 lb in. (8.0-12.4 N⋅m) of torque.

(b) Install lift fixture, 1C6955 (figure 2), onto power turbine as follows: 1

Attach hoist, rated at 6,000 lb (2,721 kg) minimum, to lift fixture, 1C6955, by engaging hoist hook in trolley clevis of lift fixture.

2

Position lift fixture, 1C6955, over power turbine assembly.

3

Lower lift fixture, 1C6955, until lift pins in legs of forward yoke align with forward holes in ground handling mount fixtures, 1C8321, on power turbine.

Figure 2. Lift Fixture, 1C6955




Raise latch and slide lift pin into ground handling mount fixture, 1C8321, on both sides of power turbine.

5

Ensure spring stop returns latch to down position to retain pin in engaged position.

6

Using ball lock pins, attach aft brackets to ground handling mounts of turbine rear frame (TRF).

(c) Remove eight capscrews, washers, and nuts that secure shipping container forward strongback cross bar to inner frame. (d) Remove three cotter pins and washers from the three dowel pins and remove three mounting pins that attach TRF handling mounts to inner frame. WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (e) Using hoist and lift fixture, 1C6955, lift power turbine from shipping container. Install into maintenance dolly, 1C9372, per WP 303 00, or into enclosure per WP 302 00. (2)

Install aft lift and turn fixture, 1C8342, onto power turbine as follows: NOTE

Aft lift and turn fixture, 1C8342, cannot be used with power turbine forward adapter installed on power turbine. (a) If installed, remove power turbine forward adapter per WP 220 00. (b) Using hoist, raise aft lift and turn fixture, 1C8342 (figure 3), and align behind TRF. (c) Using 32 capscrews, washers, and nuts, attach aft lift and turn fixture, 1C8342, to TRF aft flange. Tighten capscrews to 40-60 lb in. (4.6-6.7 N⋅m) of torque. (d) Install hoist and nylon sling onto shipping container forward strongback. (e) Remove eight bolts, washers, and nuts that secure shipping container forward strongback cross bar to inner frame. (f) Remove three cotter pins and washers from the three dowel pins and remove three mounting pins that attach TRF handling mounts to inner frame.




Figure 3. Aft Lift and Turn Fixture, 1C8342 WARNING USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (g) Using hoist(s) and aft lift and turn fixture, 1C8342, lift power turbine from shipping container. Install into maintenance dolly, 1C9372, per WP 303 00. e.

If required, install shipping container cover onto base as follows: (1)

Install 80 lbs (36.3 kg) of desiccant and shipping container hardware into proper receptacles of shipping container.

(2)

Using low power heat gun, renew humidity indicator, if necessary.

(3)

Using quad link lift, attach hoist to lift rings on shipping container cover.




WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY. CAUTION BEFORE LOWERING UPPER CONTAINER HALF, ALIGN ALL T-BOLTS IN SLOTS, TO PREVENT COCKING OF LID AND POSSIBLE DAMAGE TO FLANGE GASKET. (4)

Raise four shipping container corner alignment posts.

(5)

Carefully lift top section of container straight up.

(6)

Using nylon control lines, align top cover with base section and lower. CAUTION

ENSURE ALL T-BOLT FASTENERS ARE PROPERLY ENGAGED AND TIGHTENED BEFORE MOVING CONTAINER, OR SHIPPING CONTAINER SHALL BE DAMAGED. (7)

7.

Push all T-bolt fasteners up and through slots of upper container and turn 90 degrees (across slots). Hold T-boltheads in position (across slots) with suitable wrench or pliers. Tighten nuts to 35-43 lb ft (47.5-58.3 N·m) of torque.

Power Turbine Installation into Shipping Container. a.

Inspect shipping container per WP 504 00.

b.

If desired, move shipping container, 106C7157, to enclosure site per paragraph 6., step b.

c.

If installed, remove shipping container cover per paragraph 6., step c.

d.

Align power turbine over shipping container inner frame.

e.

If required, lower four shipping container corner alignment posts.


GEK 105054 Volume II WP 503 00 f.


Install power turbine into shipping container as follows: WARNING WHEN INSTALLING EQUIPMENT, KEEP HANDS CLEAR OF EQUIPMENT INTERFACE/ATTACHING POINTS TO PREVENT PINCH INJURY.

g.

(1)

Using hoist(s) and lift fixture, 1C6955, lower power turbine into shipping container.

(2)

Engage three inner frame mounting pins into TRF handling mounts. Secure mounting pins to TRF mounts using three dowel pins, washers, and cotter pins.

(3)

Align bolthole in shipping container forward strongback with boltholes in inner frame.

(4)

Using eight capscrews, washers, and nuts, secure shipping forward strongback to inner frame. Tighten bolts to 480-570 lb in. (54.3-64.4 N⋅m) of torque.

Remove lift fixture from power turbine as follows: NOTE If lift fixture, 1C6955, is used, install into shipping container per substep (1). If aft lift and turn fixture, 1C8342, is used, install into shipping container per substep (2). (1)

Remove lift fixture, 1C6955 (figure 2), from power turbine as follows: (a) Remove mounting pins that secure power turbine lift fixture, 1C6955, aft mounting brackets to TRF ground handling mounts. (b) Raise latch and move lift pin to disengage from ground handling fixtures, 1C8321, on both sides of power turbine. (c) Ensure spring stop returns latch to down position to retain pin in disengaged position. WARNING

USE CORRECT LIFTING EQUIPMENT AND TECHNIQUES. STAY OUT FROM UNDER SUSPENDED LOADS TO PREVENT INJURY. (d) Using hoist, lift and remove lift fixture, 1C6955, from power turbine.




Remove aft lift and turn fixture, 1C8342 (figure 3), from power turbine as follows: (a) Remove 32 bolts, washers, and nuts that secure aft lift and turn fixture, 1C8342, to TRF aft flange. (b) Lift aft lift and turn fixture, 1C8342, away from power turbine.

h.

If installed, remove ground handling mount fixtures, 1C8321, from power turbine as follows: (1)

Remove five slave bolts, in boltholes 3 through 5 and 7 and 8, on horizontal split flange of power turbine stator case.

(2)

Lightly coat engine hardware threads and contact faces with thread lubricant. CAUTION

DO NOT TURN BODY-BOUND BOLTS DURING INSTALLATION, OR DAMAGE TO POWER TURBINE STATOR CASING MAY OCCUR. (3) i.

Reinstall bolts into power turbine stator case horizontal split flange. Tighten bolts to 162-178 lb in. (18.4-20.1 N⋅m) of torque.

Prepare shipping container for shipment or storage per paragraph 6., step e.




WORK PACKAGE

TECHNICAL PROCEDURES SHIPPING CONTAINER INSPECTION AND RECONDITIONING (LEVEL 1 AND 2 MAINTENANCE) EFFECTIVITY: LM2500+ SAC - MODELS GK, GV, PK, AND PV


Change No.

Page No.

Change No.

Page No.

Change No.


Subject Shipping Container Inspection........................................................................................... Shipping Container Reconditioning Procedures................................................................

3 4


GEK 105054 Volume II WP 504 00 1.


Introduction. This work package provides inspection and reconditioning procedures for LM2500+ universal shipping containers and LM2500+ power turbine shipping containers.

2.

Reference Material. None required.

3.

Support Equipment. None required

4.


5.

Nomenclature


Desiccant Bags Chromate Free Primer Paint Epoxy Polymide Topcoat Paint Gasket Material Isopropyl Alcohol Mastic Sealant Soap Solution Thread Lubricant

MIL-D-3464 MIL-P-2444/1 MIL-C-22750 MIL-R-6855, CL-II Fed Spec TT-I-735 MIL-S-8802 Local Purchase GE Spec A50TF201 or MIL-T-5544





Shipping Container Inspection. a.

Inspect LM2500+ universal shipping containers as follows: NOTE Pay particular attention to suspension system bolts during this inspection. Shipping containers shall be inspected per following criteria prior to repair or reuse. (1)

Inspect T-bolt fasteners, nuts, and shipping container T-bolt slots for cracks, burrs, elongation, misalignment, defective threads, and other mechanical defects affecting serviceability.

(2)

Inspect braces, lifting rings, eyes, lugs, roller rings, relief valves, desiccant holders, access plate gaskets, record receptacles, and assembly guides for cracks, ruptures, deterioration, misalignment, and other defects.

(3)

Inspect closure flanges for cracks, dents, misalignment, and other defects that would affect sealing of shipping container.

(4)

Inspect closure flange gasket for permanent deformation, cuts, abrasions, or other surface defects that would affect sealing of shipping container.

(5)

Inspect shipping container top and bottom shell for dents, cracks, gouges, corrosion damage, holes, or ruptures in surface that would affect serviceability. Scratches or gouges not more than 0.062 inch (1.57 mm) deep and dents not more than 0.50 inch (12.7 mm) are acceptable without repair.

(6)

Inspect skids for broken ends, splits, dry rot, and other defects that would affect serviceability. Lengthwise splits not exceeding 2.0 feet (0.6 m) in length and 0.50 inch (12.7 mm) wide are acceptable without replacement.

(7)

Inspect shipping container shock mounts for cracks, tears, bond separation, splits, and other defects that would affect serviceability.

(8)

Use procedure outlined in paragraph 7, step d. to check pressure relief valve for proper operation.

(9)

Shipping containers reconditioned for use shall be checked for overall leakage prior to time gas generator/turbine is preserved. If shipping container is reconditioned for use and not used, pressurize and check for leaks. Use method listed in paragraph 7, step d.




(10) Inspect inner frame aft support ring and forward shipping yoke mounting pads for cracking, burrs, hole elongation, and other mechanical defects affecting serviceability. Inspect fuel manifold support brackets and vertical posts for mechanical damage. (11) Inspect forward shipping yoke and aft mounting ring for cracking, burrs, hole elongation, and other mechanical damage affecting serviceability. Inspect bolts, washers, and nuts used with aft mounting ring for thread damage. Inspect mounting pins and retainers used with forward shipping yoke for cracking, wear, or other mechanical defects. (12) Inspect shipping container finish. Refer to paragraph 7, step h. for finish requirements. Refer to paragraph 7, step j. for stenciling requirements. b.

7.

Inspect LM2500+ power turbine shipping containers per steps a.(1) through (9) and as follows: (1)

Inspect forward strongback and inner frame mounting pads for cracking, burrs, hole elongation, and other mechanical defects affecting serviceability.

(2)

Inspect forward strongback, inner frame, and mounting pins for cracking, burrs, hole elongation, and other mechanical damage affecting serviceability. Inspect bolts, washers, and nuts used with forward strongback and inner frame for thread damage. Inspect mounting pins and retainers used with inner frame for cracking, wear, or other mechanical defects.

(3)

Inspect shipping container finish. Refer to paragraph 7, step h. for finish requirements. Refer to paragraph 7, step j. for stenciling requirements.

Shipping Container Reconditioning Procedures. NOTE Reusable metal shipping containers for gas generator, gas turbines, and power turbines shall not be used for purposes other than storage and shipment of gas generators, gas turbines, and power turbines. Reusable metal shipping containers are high cost items procured and used for storage and shipment of gas generators, gas turbines, and power turbines. Strict inventory control is maintained to ensure their availability for all serviceable gas generators, gas turbines, or power turbines placed into supply system. Use of metal shipping containers is mandatory for all gas generators, gas turbines, or power turbines subject to indefinite storage and shipment. a.

Shipping containers that need minor repairs shall be reconditioned, only as necessary, to place shipping container into serviceable condition. It is unnecessary to obtain like-new appearance. Metal surfaces shall be painted per step h. of this paragraph.




CLEANING SHALL BE PERFORMED IN A CLEAN, WELL-VENTILATED AREA. PROTECTIVE CLOTHING AND GLOVES SHALL BE WORN. EXTINGUISHERS SHALL BE AVAILABLE IN CASE OF FIRE. b.

Shipping containers shall be cleaned as part of reconditioning. Any applicable procedures that follow shall be observed: (1)

Clean shipping container interior to remove fuel and oil, rags, bolts and nuts, desiccant bags, and other debris. WARNING STEAM-CLEANING CAN CAUSE SERIOUS BURNS. WEAR PROTECTIVE GLOVES, APRON, AND FACE SHIELD DURING STEAM-CLEANING PROCESS. SOLVENT IS FLAMMABLE AND IRRITATING TO THE SKIN, EYES, AND RESPIRATORY TRACT. USE GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING AS NECESSARY. USE IN WELL-VENTILATED AREA OR AN APPROVED CLEANING CABINET. KEEP AWAY FROM HEAT, SPARKS, AND OPEN FLAME.

(2)

Solvent spray or steam-clean shipping containers that require rust removal and refinishing in order to ensure clean and workable surface. WARNING

BLASTING OPERATIONS CAN PRODUCE AIRBORNE PARTICLES THAT ARE HARMFUL TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN, EYE, AND RESPIRATORY PROTECTION IS REQUIRED. (3)

Thorough sandblasting shall be required for shipping containers that need complete internal or external refinishing. CAUTION

USE CARE TO AVOID DIRECT APPLICATION OF STEAM JET TO RUBBER PORTIONS OF SHOCK MOUNTS, OR MOUNTS MAY BE DAMAGED. (4)

Prior to steam-cleaning, remove relief valves, closure flange gaskets, and other parts that may be damaged by steam-cleaning methods. It is not necessary to remove shock mounts, but care shall be taken against direct application of steam jet against rubber portions of mounts.


GEK 105054 Volume II WP 504 00 (5)

LM2500+ SAC GE Industrial AeroDerivative Gas Turbines Remove loose and excessive rust from shipping container internal and external surfaces including inner frame, desiccant baskets, attaching hardware, and closure flange gasket surfaces. Use wire brush or sandblasting. Bolts, mounts, and other fasteners that are excessively corroded should be removed for replacement or chemical cleaning and plating as desired. CAUTION

COVER OBSERVATION PORT AND/OR PRESSURE VALVE OPENINGS DURING RUST REMOVAL OR CLEANING OPERATIONS.

c.

(6)

During rust removal or cleaning operations, in vicinity of installed inspection windows or pressure valves, cover openings to prevent damage or contamination.

(7)

Remove all mounting hardware, rubber shock mounts, nuts, bolts, valves, skids, etc., that have been selected for replacement during inspection specified in paragraph 6.

(8)

Set aside relief valves for inspection and test in accordance with step d. below.

Shipping container surfaces shall be reworked as needed as part of reconditioning. Any applicable procedures that follow shall be observed: WARNING WELDING OPERATIONS SHALL BE PERFORMED BY EXPERIENCED AND TRAINED PERSONNEL. APPROVED SAFETY PROCEDURES AND PROTECTIVE EQUIPMENT SHALL BE USED. CAUTION DO NOT ATTEMPT TO WELD SHIPPING CONTAINERS WHEN PRESSURIZED. (1)

Weld repair cracks, tears, ruptures, or holes in shipping container shell that shall affect serviceability.

(2)

Repair gouges and scratches beyond 0.062 inch (1.57 mm) deep and dents not more than 0.50 inch (12.7 mm) deep by fill-welding.




WEAR PROTECTIVE GLOVES TO PREVENT INJURY FROM SHARP EDGES AND ROUGH SURFACES. (3)

Repair holes and ruptures in shipping container shell by hot forming or straightening any irregularities around damaged area and welding on suitable patch (figure 1). Fabricate patches from 10 or 11 gage hot rolled steel. Extend edges of patch at least 0.50 inch (12.7 mm) in all directions beyond damaged area. All patches are to be installed onto outside of shipping container only. WARNING

WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS. (4)

Straighten dented or deformed closure flanges by means of hot forming.

Figure 1. Patch Repair of Shipping Container Shell - Typical 7 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



PARTICLES FROM GRINDING OPERATIONS CAN DAMAGE EYES AND RESPIRATORY TRACT. EYE AND RESPIRATORY TRACT PROTECTION IS REQUIRED. (5)

Repair any defects in closure flanges such as scratches, gouges, nicks, or rust pits, that would interfere with effectiveness of seal by fill-welding and flush grinding. Use suitable gages to check for flushness of repaired area. Scattered pits not exceeding 0.062 inch (1.57 mm) in depth do not require fill-welding but do require use of wire brush loose for rust removal.

(6)

Restore mismatched upper and lower shipping container halves to service as follows: (a) Install top cover onto shipping container. (b) Align greatest possible number of attaching holes with installation T-bolt fasteners. (c) Repair misaligned holes whenever possible by elongating hole to maximum of 0.250 inch (6.35 mm). Maintain minimum of 0.250 inch (6.35 mm) distance from outer edge of hole to outer edge of flange. (d) Holes that cannot be aligned by elongating should be fill-welded, ground flush, redrilled, and re-formed. NOTE

Mating surface flange and groove areas require refinishing with at least two coats of chromate free primer paint, prior to installation of seal. (7)

Repair gussets, bumper guards, braces, lifting rings, rollover rings, etc., by straightening, as necessary, and welding any cracks or breaks. All shipping containers that have weld repairs accomplished shall be carefully checked for leaks in weld area at time of pressurization. CAUTION

DO NOT ATTEMPT TO WELD SHIPPING CONTAINERS WHEN PRESSURIZED. d.

Relief valves shall be checked for proper type of valve, release pressure, and for leakage following resetting. Relief valves shall release at 0.5-1.5 psig (3.45-10.34 kPa). Apply soap solution. Relief valves shall be bubble free at 0.5 psig (3.45 kPa). Inspect and recondition valves as follows: (1)

Replace preformed packing seats in valve, as necessary, to accomplish sealing.




e.

f.

(2)

Use threading taps or rotary wire brushing to remove excessive thread rust in relief valve receptacles.

(3)

If relief valve threaded openings are oversized, retap openings and install standard pipe bushing of appropriate size.

(4)

When reinstalling relief valves, coat threads with thread lubricant.

Inspection and reconditioning of wooden skids shall follow these general rules: (1)

Inspect skids for deterioration, damage, or loose bolts.

(2)

Wood used for skid refurbishment shall be pretreated.

(3)

Check skids or wood intended for skid replacement for freedom from defects. Small knots are allowed. Knots that have diameter greater than 1/4 width of board are to be avoided.

Removal of water traps shall be accomplished as follows: WARNING VAPOR FROM UNCURED SEALANT IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. AVOID CONTACT WITH SKIN AND EYES. USE IN A WELL-VENTILATED AREA.

g.

(1)

Any cavities, such as gussets, weld joints, deep rust pits, and dents that shall form water traps when shipping container is in its normal storage position, shall be filled with suitable mastic sealant per MIL-S-8802.

(2)

Voids shall be caulked with sealer after welding and before painting.

Inspect, clean, and recondition gaskets as follows: NOTE Replacement gaskets may be fabricated locally. All joints shall be vulcanized to form continuous gaskets. (1)

Replace any flange gaskets with cuts, abrasions, or other surface defects that would affect sealing of shipping container.





To ensure proper sealing of gaskets, clean all gasket sealing surfaces with isopropyl alcohol. WARNING

PAINTS, PRIMERS, AND THINNERS ARE FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. USE IN A WELL-VENTILATED AREA. FOR SPRAY APPLICATIONS, RESPIRATORY PROTECTION IS ALSO REQUIRED. CAUTION AFTER PAINTING ANY SURFACES OF SHIPPING CONTAINER, ALLOW PAINT TO CURE (DRY) FOR 48 HOURS MINIMUM PRIOR TO CONTAINER USAGE. h.

Surface refinishing of shipping containers shall be accomplished as follows: NOTE All surfaces shall be thoroughly cleaned inside and outside, and all debris removed before application of any finish coatings. (1)

Ensure surfaces are ready for paint application. If any questionable areas are observed, clean areas per paragraph 7, step b.

(2)

At least 25 percent of total area may be bare of paint before complete refinishing is necessary.

(3)

Whenever possible, original paint tones shall be used for touch up paint. Matching of colors is not necessary. NOTE

Use of special purpose paint colors such as red or yellow shall be avoided. (4)

When completely refinishing any painted surface, paint area as follows: (a) Apply one coat of chromate free primer paint. (b) Apply one coat of topcoat paint to match surrounding color.



i.


(5)

Interior touchup shall consist of mist coat of chromate free primer paint, followed by wet coat of same material.

(6)

When complete interior finish is necessary, second coat of chromate free primer paint shall be continuous and without gross runs or sags. As an alternate, two coats of chromate free primer paint followed by finish coat of topcoat paint of any suitable color shall be acceptable.

(7)

Exterior touchup shall include coat of chromate free primer and coat of topcoat paint.

(8)

Complete exterior finishing shall consist of two coats of chromate free primer and at least one coat of appropriate topcoat paint. Painting shall include closure flange, mating surfaces, and grooved areas that come into contact with closure seals.

The LM2500 universal shipping container stencils shall be placed per approximate locations shown. Stencils shall be applied or renewed onto shipping container as follows: (1)

All sides of shipping container (figures 2 and 3), use 1.00 inch (25.4 mm) characters. CAUTION: RELEASE PRESSURE BEFORE OPENING CONTAINER

(2)

Record receptacle end of shipping container (figure 2) per the following: (a) Use 0.50 inch (12.7 mm) characters: CAUTION: FOR AIRFLOAT TIEDOWN OR TOWING EMPTY CONTAINER ONLY DESICCANT RECEPTACLES AND PRESSURE RELIEF VALVE HUMIDITY INDICATOR OBSERVATION PORT (b) Use 1.00 inch (25.4 mm) characters: RECORDS



LM2500+ SAC GE Industrial AeroDerivative Gas Turbines (c) Use 2.00 inch (50.8 mm) characters: MGW TARE NET CUBE WIDTH HEIGHT LENGTH (d) Solid black paint to area 10 by 24.25 inches (25.4 by 61.6 cm).

(3)

For top of shipping container (figure 2, detail A) per the following: (a) Use 4.00 inch (101.6 mm) characters: WARNING (b) Use 2.00 inch (50.8 mm) characters: FOR COVER LIFT ONLY

(4)

For sides of shipping container (figure 3) per following: (a) Use 1.00 inch (25.4 mm) characters: SHIP ON AIR RIDE EQUIPPED TRAILERS ONLY LIFT HERE SET/LIFT LUG TIE DOWN (b) Use 2.00 inch (50.8 mm) characters: LM2500 (c) Use 4.00 inch (101.6 mm) characters: DO NOT DROP (d) Use 1.00 by 5.00 inch (25.4 by 127.0 mm) arrows.

(5)

For inner frame of shipping container (figure 4) per following: (a) Use 1.00 inch (25.4 mm) characters: GT GG GG PLUS GT PLUS




Figure 2. Universal Shipping Container-End View 13 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 3. Universal Shipping Container-Side View 14 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 4. Universal Shipping Container-Inner Frame 15 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

GEK 105054 Volume II WP 504 00 j.


The LM2500 power turbine shipping container stencils shall be placed per approximate locations shown. Stencils shall be applied or renewed onto shipping container as follows: (1)

For all sides of shipping container (figures 5 and 6) in 1.00 inch (25.4 mm) characters use: CAUTION: RELEASE PRESSURE BEFORE OPENING CONTAINER

(2)

Record receptacle end of shipping container (figure 5) per following: (a) Use 0.50 inch (12.7 mm) characters: DESICCANT RECEPTACLES AND PRESSURE RELIEF VALVE HUMIDITY INDICATOR OBSERVATION PORT (b) Use 1.00 inch (25.4 mm) characters: RECORDS (c) Use 2.00 inch (50.8 mm) characters: MGW TARE NET CUBE WIDTH HEIGHT LENGTH

(3)

For top side of shipping container (figure 6) per following: (a) Use 2.00 inch (50.8 mm) characters: WARNING (b) Use 2.00 inch (50.8 mm) characters: FOR COVER LIFT ONLY

(4)

For lower sides of shipping container (figure 6) per following: (a) Use 1.00 inch (25.4 mm) characters: SHIP ON AIR RIDE EQUIPPED TRAILERS ONLY




(b) Use 2.00 inch (50.8 mm) characters: LM2500 LPT (c) Use 4.00 inch (101.6 mm) characters: DO NOT DROP (5)

For base sides of shipping container (figure 6) per following: (a) Use 1.00 inch (25.4 mm) characters: LIFT HERE TIE DOWN (b) Use 1.00 by 5.00 inch (25.4 by 127.0 mm) arrows.




Figure 5. Power Turbine Shipping Container-End View 18 GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.



Figure 6. Power Turbine Shipping Container-Side View 19/(20 Blank) GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.

Gek105054 LM2500 Plus O&M Manual

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