LM2500 WTUI 2015

Western Turbine User’s Inc. LM2500 Session March 15- 18, 2015 | Long Beach, CA

Imagination at work

GE Information—U.S. Government approval is required prior to export from the U.S., re-export from a third country, or release to a foreign national wherever located.

Agenda • Introduction • Fleet statistics • Completed/Active programs • Services programs • Operations & Maintenance/LMTD highlights • Supporting material

WTUI Conference March, 2015

© 2015 General Electric Company – All rights reserved.

Introduction

LM2500 GE participants Participant

Title

Mike Pipes Kirk Wiedman Terry Khera Nate Yux Gaurav Tyagi Wayne Robbins Steve Payling

Services Product Manager Fleet Program Manager Consulting Engineer Product Support Engineering CM&U Engineering Program Manager Product Line Manager



Fleet statistics

LM2500 fleet – close to 1,400 installed units 25+

LM2500+ & LM2500+G4

25

LM2000 & LM2500

mul

Multiple Models at same site

As of July 2014 WTUI Conference March, 2015


LM2500 highlights • LM2500 fleet crosses 72M+ operating hours with over 2,000 delivered engines • Dual fuel DLE engine demo with Modified Wobbe down to the low 20’s • +G4 DLE site with expected C2+ concentrations of up to 27% now fully operational

GE Houston fuel flex test facility

• Recent LNG facility with 10 LM25+G4 units reached full production capacity ahead of schedule • Dual fuel DLE DP package now available for onshore power gen LNG facility



LM2500 field events - engine

Thrust Bearing Algorithm Updated



Completed programs

LM2500/+/+G4 completed engine programs LM2500+/+G4 VSV Torque Shaft Bearings HPC Stg 13 Blade

HPT Stg 2 Nozzle Support & Cooling Air Tubes (Spoolies)

Hot Restart (4 hr Lock Out Avoidance) Bulletin LM2500-IND-248 LM2500-IND-249 LM2500-IND-254

Title

VSV Torque-Shaft Bearings – Fwd VSV Torque-Shaft Bearings – Aft Stage 2 HPT Stator Nozzle Support and Cooling Air Tube Improvement


Category Routine Campaign Campaign

Timing Level Code F F D

6 6 6


VSV torque shaft bearings

Applicable to: SAC Base Plus  +G4 

DLE

 

Background • Wear on aft spherical bearings – TSN 9,700 – 30K hrs

Investigation status • Service evaluation completed – Greater than 16K hrs with no wear noted

Aft bearing wear

Enhancement plan/Recommendations • Issued Service Bulletin 248 (FWD) & 249 (AFT) – Field replaceable aft bearing housing – Enhanced material wear couple – Enhanced axial load capability with full contact spherical bearing WTUI Conference March, 2015

Full contact bearing/ field replaceable design


LM2500/+/+G4 HPT S2N cooling tube

Applicable to: SAC Base  Plus  +G4 

DLE

  

Background • HPT S2N cooling tubes (spoolies) rotate, turn and are cut in service – Wear debris from spoolies migrate into flow path • Potential for domestic object damage on stage 2 blades and nozzles

Investigation status • Cooling tubes turn and rotate in service causing wear • Sharp spring washer cuts into tube and create debris • Debris migrates into flow path through cooling passages WTUI Conference March, 2015

Impact Damage on S2B




DLE

  

Enhancements • Eliminated spring washer – no sharp edges cutting into cooling tube • Tube OD increased for press fit - stop relative motion and wear • Bearing surface increased – keeps tubes from flipping in Ferrule – Spoolie height Increased – Ferrule lower chamfer eliminated

Increased bearing surface

Current bearing surface





DLE

  

Field recommendation • Follow O&M practices per GE manuals • Service Bulletin 254, issued July 2014 – Replace cooling tubes per latest design at next hot section exchange or overhaul – Rework instruction available for collar replacement at repair



Restart requirement updates


DLE

  

Background • Engine damage may occur if restart is accomplished after a hot shutdown – 4-hour lockout requirement was introduced to avoid hardware damage

• O&M manuals updated in 2013 with new re-start recommendations and options

Update • Restart requirements were clarified May, 2014 via Interim Change Notice (ICN) – Table added to show restart options – Time to restart after hot shutdown clarified

Recommendations • Work with Packager to ensure software meets updated restart requirements WTUI Conference March, 2015


Restart requirement updates


DLE

  

START MOTOR START or MOTOR Initiated within 6 minutes of GG Initiated within 6 minutes of GG reaching 300 NOT Initiated within 6 minutes of GG reaching reaching 300 rpm rpm 300 rpm Motor Normal Shutdown with 5 min idle

Hung or Failed Start or Trip when T48 <1150F for over 8 minutes

(3)

Normal start permitted

2000-2400 rpm 12-15 minutes or Slow Motor(2).

Normal start permitted any time during motoring or after motoring is complete. Motor

(3)

(1)

Soft Start recommended

2000-2400 rpm 12-15 minutes or Slow Motor(2).


(1)

Soft Start recommended

Normal start permitted any time during motoring or after motoring is complete. (3)

Emergency Shutdown with T48 >1150F


Motor 1000-1200 rpm for 12-15 minutes minimum, then continue until T48 <400F. Normal start permitted any time during motoring or after motoring is complete. or Slow Motor

Emergency Shutdown No motoring (ESN)

(2)

Soft Start(1) required or 4 hour lockout required

(1)

followed by Soft Start .

Soft Start(1) or 4 hour lockout required after cause of trip is determined.

(1) SOFT START: Confirm free rotation by applying 45 ft-lbs to AGB manual drive shaft. Within 6 minutes, Motor @ 1000 -1200 rpm for 20 minutes, then begin normal purge and start cycle. Risk of HPC/HPT rubs if Soft Start is not completed. (2) SLOW MOTOR: If motor is not already rotating, confirm free rotation by applying 45 ft-lbs to AGB manual drive shaft. Within 6 minutes, Motor @ 80 120 rpm for up to 4 hours. Risk of HPC/HPT rubs if Slow Motor is not completed. Continuous Slow Motor can be used to prevent lock-up. (3) Scavenge temp <340F during all Motoring.



HPC stage 13 blade trailing edge corner loss


DLE

  

Background • HPC Stg 13 Trailing Edge corner loss observed regardless of 4 hour lock out procedures

Investigation status • Tip rub observed on some engines after production acceptance test • Blade TE corner loss is due to blade tip rub and propagated in HCF



HPC stage 13 blade trailing edge corner loss


DLE

  

Enhancement plan • Increased clearance to reduce the probability of rubs between the blades and casing – Leading Edge: 0.005"

0.005 in.

– Trailing Edge: 0.010”

Fwd

0.010 in.

Aft

Field recommendations • Updates to IRM manual to open up the tip clearance in next revision



Active programs

LM2500 fleet active engine programs HPC Stg 16 Blade

VSV Turnbuckles

CDP bleed valve Core software logic releases Sandworm Cyber Security



VSV turnbuckles


DLE

 

Background • Wear found on HPC VSV turnbuckle and clevises on LM2500+/+G4 (seen at ~4000 hrs)

Investigation status • Relative motion between turnbuckles contribute to wear with metal contact Clevis

Clevis Turnbuckle



VSV turnbuckles


Enhancement plan

DLE

 

Washer

•

A flat-washer between clevis and turnbuckle to avoid metal to metal contact (Polyimide Carbon Fiber Composite)

•

Anti Rotation devise mounted on turnbuckle

Field recommendations •

Install to reduce wear and inspect at 8000 hrs.

•

Service Bulletin and kits targeted March 2015 IGV

0

Link Assembly

1 2 3 45 6

Hose Clamp


Anti Rotation Device


HPC stage 16 blade platform cracking


DLE

  

Background • Platform distress noted on Inco718 blades at two sites • Both units operated with increased corrected core speed

Investigation status • Bench fatigue testing and analysis identified platform mode • Shaker table tests duplicated blade fracture initiation location and mode



HPC stage 16 blade platform cracking


DLE

  

Enhancement plan • Defined optimum platform corner crop – Blade stress enhancement – Negligible impact on performance/operability • Field evaluation in process

Field recommendations • Field implementation planned in 2015



LM2500/+/+G4 DLE CDP bleed valve

Applicable to: SAC Base Plus +G4

DLE

  

Background • Customers have experienced CDP bleed valve removal at low time – Oil leakage and/or LVDT feedback error typically cause removal – Recent events linked to cyclic operation • Same valve design used on LM6000

Link chamber LVDT

Actuator Housing

Butterfly Shaft

Bearing (Carbon Spacers Missing) WTUI Conference March, 2015




DLE

  

Enhancement status • Software changes identified for new products to address valve reliability (decreasing valve activity) – 2nd order filter for noise – Rate limit – slows valve actuation – Freeze window expansion • flame temperature from 20 deg F to 40 deg F – Engine test was performed 1Q2014





DLE

  

Enhancement status (continued) • Service evaluation for potential new supplier • LM6000 2.5”/6” bleed valve service evaluation beginning 4Q14 • LM2500 4” bleed valve service evaluation beginning 1Q15 − Need to identify sites with following operation profile •

High cycling (load following) continuous operation

•

RM&D for continuous monitoring

• Score now approved as licensed repair source for Honeywell manufactured bleed valves WTUI Conference March, 2015


Core software logic releases


DLE

  

Engine model

Mark VI

Mark VIe

Micronet+

RX3i

Description

Base SAC

N/A

N/A

PE/1.0.0

N/A

Gas only, no specs

Base DLE

PJ/5.0.0 N/A PJ15/1.1.0

PJ/5.0.0 N/A PJ15/1.1.0

PJ/5.0.0 PJ/1.1.0 N/A

PJ/5.0.6 N/A N/A

Gas only Dual fuel 15 PPM

Plus SAC

N/A N/A

PK/6.1.0 N/A

PK/6.0.0 PK/5.1.0

PK/6.1.01 N/A

Dual fuel (with PFC) Medium BTU fuel

Plus DLE

N/A N/A N/A

PR/4.4.0 PR/5.0.0 PR15/1.2.01

PR/4.5.0 PR/5.0.0 N/A

PR/4.5.2 N/A PR15/1.2.01

Gas only Dual fuel 15 PPM

+G4 SAC

N/A N/A

RA/4.0.0 N/A

RA/4.2.0 RA/2.3.0

RA/4.0.2 N/A

Dual fuel (with PFC) Low/Med BTU fuel (PFC)

+G4 DLE

N/A N/A

RB/3.1.0 N/A

RB/3.1.0 RB/3.1.0

RB/3.1.4 RB/3.1.4

Gas only Dual fuel 1 work in progress

To determine your version … contact your Packager or GE Service Manager WTUI Conference March, 2015


Cyber Threat Notification – Sandworm Background

Applicable to: Base Plus +G4

A group of adversaries named “Sandworm” is implementing a targeted campaign against select targets in the United States and abroad. Among the attack vectors, adversaries may engage in phishing campaigns, leverage known and 0-day vulnerabilities and target vulnerable Industrial Control Systems (ICS), SCADA and HMI systems routable through public networks.

Investigation status

• Based on Technical Information Letter (TIL) 1951 GE’s controls engineering for Distributed Power Gas Turbines recommends customers to follow GE Intelligent Platforms (GE-IP) Product Security Advisory KB16399 , which in summary, states:  Customers running CIMPLICITY HMI versions 8.2 SIM 23 and earlier should upgrade to CIMPLICITY Version 8.2 SIM 24 or latest SIM available.  If customers are unable to upgrade their CIMPLICITY version, they should follow guidelines in GEIP14-05 “Other Recommendations” section in order to protect their control networks until a time where an upgrade may be possible. Users Conference for GE’s Distributed Power business| February 2015


SAC TBD TBD TBD

DLE TBD TBD TBD

Cyber Threat Notification – Sandworm

Applicable to: Base Plus +G4

Field Recommendations

• Currently, GE’s controls engineering for Distributed Power Gas Turbines is working on identifying sites that may possibly be affected and will publish a Product Bulletin or Service Letter in early 2Q targeting customers who may be affected.

Users Conference for GE’s Distributed Power business| February 2015


SAC TBD TBD TBD

DLE TBD TBD TBD

Services programs

Maximize your LM2500 asset investment Upgrade options deliver customer value by using proven technology and OEM experience From: To:

LM2500 SAC LM2500 SAC

LM2500 DLE

LM2500+ SAC

Available

LM2500+ DLE Available

LM2500 DLE

*Available (17)

Available (1)

LM2500+ SAC

Available

Upon Request

LM2500+ DLE

Available

Available

Available (1)

LM2500+G4 SAC

Available

Upon Request

Available (6)

Upon Request

LM2500+G4 DLE

Available

Available

Available

Available (1)

Available

Over 30 LM2500 conversions successfully completed to date WTUI Conference March, 2015


LM2500/+/G4 repowering options Advantages • Range of power from LM2500 base to LM2500+G4 • Reduced scope = reduced project cost • Retains existing generator/lube oil system • Can be customized to fit into challenging existing spaces • Maximize use of existing infrastructure • Power generation or compressor drive


LM2500 “Universal Repower” package


LM2500 repowering experience 35 units to date



LM2500 SAC to DLE conversion Space occupied by DLE manifolds & feeder tubes

DLE cross section

SAC dry cross section Space required to install DLE shut off & metering valves


Existing package floor


LM2500 to LM2500+ upgrade LM2500+ New stage zero blisk

New HPT materials And cooling upgrades

Increased sizing on LPT disks

LPT airfoil flow function Opened up by 10% ~14 inches

LM2500 WTUI Conference March, 2015


Controls platform upgrades Challenges • Limited maintenance support • Limited parts availability • Stable and reliable operation • Updated turbine control systems are not HW and SW compatible GE retrofit controls - customer value • Complete upgrade to state of the art turbine controls • Seamless integration with existing plant eqipment • High level of customization and flexible solutions • Reuse of existing infrastructure • Access to latest turbine core software technology. • Access to GE field service support for maintenance • DCS and plant wide integration



Vibration panel upgrades LM2500

LM5000

LM6000

LMS100

Customer value • Highly configurable • Easier spare parts management • Multiple displays can be connected concurrently • Lower installation costs Users Conference for GE’s Distributed Power business| February 2015


Reliability Operability

Bently Nevada 3500 - product description • The 3500 System provides continuous online vibration monitoring • Capable and flexible system with rack-based design • Reliable vibration monitoring system with selfchecking and fault tolerant features • Highly configurable with various levels of redundancy • Allows mission-critical applications to be addressed

LM2500 4-hour lockout avoidance Background


DLE

  

The current LM2500/+/G4 package is forced into a 4 hour lockout condition if it is not restarted within 6 minutes or continuously cranked after an emergency hot shutdown.

Enhancements

• CM&U upgrade kit enables the engine to slowly rotate for cool-down until restarted or cooled − Upgrade includes hydraulic start system & control system logic − 4 hour lockout avoidance for over 66% of emergency shut-down conditions

Field recommendation • Kit available for delivery WTUI Conference March, 2015


LM2500 starter clutch


Background

DLE

  

• Current Hilliard clutch requires inspection every ~10,000 hours • Requires clutch to be sent back to vendor for inspection or service if wear is shown during 10K inspection

Enhancements • New supplier clutch to enhance reliability • 25,000 hour inspection & maintenance interval • About 60% weight reduction over Hilliard clutch

Vs.

Field recommendation • Contact your GE Service Provider for starter/clutch options WTUI Conference March, 2015


Distributed Power legacy portal GE Aviation Customer Web Center (CWC) gas turbine focused

Retiring ~March 2015 … All the functionality moved to the Distributed Power Services portal … Contact your Service Manager to get access to the new portal Users Conference for GE’s Distributed Power business| February 2015


Distributed Power Services portal www.ge-distributedpowerportal.com Core Use Cases

1

View fleet intelligence: RM&D data and plots, alarms, advisories

2

3

4

Major Components

Access technical publications: bulletins, service letters, engine manuals, reports Monitoring

Publications

Discussions

Forums

Participate in collaboration forums with customers and GE Experts

Ease of use, cloud-based solution



Distributed Power Services portal Monitoring

Publications

Fleet Intelligence • Trend 2 years of historical data

Technical Documents • 8000+ technical publications

• Trend up to 16 data tags at one time • Access RM&D issued advisories

• Download service bulletins/letters, conf materials, depot reports, and engine manuals

• Download parametric & alarm data downloads

• Access & update bulletin compliance details

• Post plots to discussions for further dialogue

• Upload user conference materials

Discussions

Collaboration • A collaboration forum between one customer org and GE experts • Comment, like, and share posts with members of the customer org • Discuss topics directly with GE experts • Review & acknowledge RM&D advisories


Forums

Collaboration • A collaboration forum accessible to all customers and GE experts • Discuss industry or product line related topics • Access executive messages broadcasted from the Product Mgmt team


RM&D advanced analytics can help: •

• • •

Improve RELIABILITY with early issue detection & preventive Monitor – Analyze maintenance Increase AVAILABILITY with OEM backed issue resolution

GE Monitoring Center

Customer Site Data Acquisition FireWall System

– 24/7 Support – Insight - Action Connectivity

GE Customer Portal

Reduce maintenance costs for additional PRODUCTIVTY Operator

•NSD LIMIT

•ALERT

Secure central database

Control System

Enhance PERFORMANCE with diagnostics and recommendations

Automated Analytics

RM&D Technicians & Customer Support Center

ALERT

Remote Troubleshooting Assistance

Monitor – Analyze – 24/7 Support – Insight - Action



GE aeroderivative CM&U standard products



Operation & maintenance /LMTD highlights

GE Operation and Maintenance manual (O&M) Ex. GEK 105054 LM2500+ SAC, V1, Chp 11 Preventive Maintenance

Note: •For Peaker application also see SL LM2500-I-05-002 “Humidity Control in LM Packages to Prevent Corrosion Fatigue •O&M Appendix A , Fuel specification MID-TD-0000-1&2 WTUI Conference March, 2015


Location of lifting areas for hoist and for forklift LM2500 universal container P/N 106C7156P04 Top lift locations are for hoist

Lift lugs for use with special tooling “shoes” P/N 1C8017

Bottom lift locations are for forklift transportation WTUI Conference March, 2015


LM 2500 universal shipping storage container

Breather valves and desiccant ports

Humidity indicator

106C7156P04 shipping and storage container forward looking aft



LM 2500 universal shipping storage container Aft strong back Forward mounting yoke

Container lift bracket located on top section 4 locations

Mounting bar stenciling yoke placement locations

Container with wop removed Internal mounting exposed

Mounting bar stenciling aft strong back locations



LM 2500 universal shipping storage container General maintenance 1. Inspect humidity indicator A) If the element in the center of the indicator is blue the desiccant is still active B) If the element in the center of the indicator is pink the desiccant inside the container will require replacement and the litmus paper in the indicator needs to be replaced.

2. Inspect the lifting brackets A) Inspect the lifting brackets closely for damage, degradation, or cracked welds. If any damage is observed the brackets should be repaired and retested prior to use. Along with this the lift datum plate, located on forward end of container should be updated with this data.

3. Inspect closure gasket A) With container cover removed inspect the closure gasket at container split line for any splits. If any damage is observed replace with new closure gasket.

4. Inspect internal mounting attachments points for missing or damaged pieces. Contact your GE Service Provider for repair/replacement with GE Asset Mgt WTUI Conference March, 2015


GG/GT preservation, depreservation & storage maintenance Reference appropriate O&M manual Work Package to properly Preserve, De-preserve and Store Gas Generators/Gas turbines Note: Detailed preservation specification will be added to O&M manuals also a Service Letter will be issued



Package Best practices/ Supporting material

Entry into GE package during operation • Not recommended per GE Product Letter 9 May, 2008 – PL1600-08-01, PL2500-08-01, PL5000-08-01, PL6000-08-03, LMS100-08-01 • Any previously published package entry procedure in the GE O&M manual is superseded by the applicable Product Letter above • Potential Hazards during operation (but not limited to) – High speed rotating equipment – Hot surfaces – High sound levels – High velocity air – Hydraulic and Electrical devices • In the event that package entry is required during operation, contact GE for support

WTUI Conference March, 2015 Users Conference for GE’s Distributed Power business| February 2015


Engine/package documentation Example – O&M Manual, periodic inspection tables



Engine/package documentation Example – IPB



Engine/package documentation Example – Service/Product Bulletin



Engine/package documentation Example – Service/Product Letter



Engine/package documentation Example – F&ID drawing



Engine gas path cleanliness Necessary for optimum power output Necessary for borescope inspections • Internal parts easily viewed when clean • Reference OEM Packager manual for instructions Waterwash variables • Local site environment determines waterwash frequency − Trend power output over time to determine schedule • Effectiveness of waterwash detergent − Some more effective than others on different contaminants • Heated water is more effective for washing and rinsing • Rinse very well (multiple rinses) − Detergent on blades/vanes contributes to fouling • On-line wash is not substitute for off-line wash − Only extends time between off-line washes • Inspect waterwash nozzles per packager’s O&M manual WTUI Conference March, 2015 Users Conference for GE’s Distributed Power business| February 2015


High speed data and trending • •

Extremely valuable for troubleshooting engine and package issues Mk6 uses the TREND RECORDER in ToolBox − User definable points, triggers & collection speeds − Must be set up prior to use!

•

Woodward uses the DATALOG generated in control, viewed with Control Assistant − Preset with the most important engine data − collection speed is as fast as logic updates (10milliseconds for some)

• • •

Most HMI’s have user definable points Contains points from both Fuel Control and Sequencer Slower data stream than the High Speed Data collectors found in Fuel Controller. Typically about 1-2 seconds or slower per update

Who knows how to take a data log? WTUI Conference March, 2015 Users Conference for GE’s Distributed Power business| February 2015


Alarm resolution •

Implement an Alarm Process and Resolution scheme at each site

•

There are no “nuisance” alarms – Fully investigate each alarm − Repeated alarms need instrumentation, hardware, process or logic reviewed for change or enhancement

•

Do not get stuck in the paradigm “the alarm always comes on” − Take action to reduce the alarm load on operators so they do not “Re-set it and Forget it” − Review data and control system set-points to verify the conditions causing the alarm − Define alarms that are problematic as just a few alarms typically drive the daily alarm count above acceptable levels

•

Periodic maintenance practices (Instrumentation and mechanical inspections) offer the best prevention of nuisance type alarms



HMI software back-up •

Human Machine Interface (HMI) is a computer – –

Monitor, hard drive, mother board and a read/write drive Typically runs Cimplicity, Wonderware®, Citect, iFix Intellution or other application software

•

The key to timely repair of your HMI is availability of a duplicate of the HMI’s hard drive image

•

Customers should invest in commercially available software to backup the HMI hard drive in its entirety –

•

Able to reproduce their HMI configuration on a replacement hard drive without GE intervention and possibly the purchase of costly replacement application software

Reference Product Letter LM6000-IND-08-002, LM2500-IND-08-002



Oil/Water/Fuel sampling • •

• •

Follow packager O&M manual for sampling frequency & limits Oils (turbine, generator, hydraulic start) − − −

Particle counts, chemistry, water content, acidity Flush/drain as required by sample analysis results Recommend no mixing of different brands & manufacturers

− −

Suspended solids, dissolved solids, pH, and conductivity No particles > 20 micron

Air/Water/Fuel Combined (all sources) – Sodium and potassium < 0.2 ppm Water (Nox, SPRINT*)

•

Liquid Fuel

−

Meets GE Specifications prior to going into the storage tanks Constantly analyzed − Particle counts, chemistry, water content No particles > 20 micron

− −

•

− − −

Gas Fuel

Lower Heating Value and Specific Gravity Entrained Liquids and Dew Point (50 deg F Superheat required) Contaminants

*Trademark of General Electric Company WTUI Conference March, 2015 Users Conference for GE’s Distributed Power business| February 2015


DLE – maintaining optimum operations Symptoms • • • • •

Excessive CO/UHC Excessive NOx High acoustics Erratic/forced staging Unable to transition

Causes • • • • • •

Flame temp low Flame temp high Excessive WF36/WA36 Calibration of air systems Calibration of fuel flow Fuel properties

Action • •

Ensure Fuel/ Air flow systems are calibrated Correct measurement of fuel properties



DLE – maintaining optimum operations Basic engine model: Depicts how measured pressures, temperatures, speeds, geometry and fuel are used for control



DLE – Simple do’s Chromatograph/Calorimeter maintenance • Daily Auto Calibration recommended • Instrument kept in stable environment for best results • Quality Calibration (Cal) gas & Carrier Gas − Cal gas bottle temperature above dew point for highest dew pt constituent

• Spares available onsite for long lead items to avoid going manual Air/fuel leaks • Perform fuel system leak checks prior to start up and during engine swaps • Track long term flow function shifts (NOZZZTOFF’s) • Track heat rate vs. output for leak indication • Monitor package temperature probes vs. ambient conditions Instrument calibration & electrical system verification • Calibration schedule per OEM manual for all instrumentation − Airflow pressures & temperatures, acoustic system, fuel system GP pressures − Yearly analog screen confirmations

• • •

Yearly loop integrity confirmations Check staging and bleed valve operation Check variable geometry WTUI Conference March, 2015 Users Conference for GE’s Distributed Power business| February 2015


Do not remap until … …the problem is understood • Emissions, acoustics trips, blowouts... • In what mode is problem prevalent (BRNDMD=?) • Steady state, transient −

For Transient acoustics, capture high speed data file (10 msec data)

• Low power or high power When was problem first observed • Gradual change over a period of months? • Step change What to do first… • Verify gas property inputs to control • Does gas composition meet O&M specifications (MIT-TD-0000-1) • Review Gas Analysis Equipment Installation (SL-LM2500-IND-99002) • Water wash - if compressor is dirty or efficiency is down Dry Low Emission (DLE) engine design depends on the precise control of the flame temperature during the combustion process WTUI Conference March, 2015 Users Conference for GE’s Distributed Power business| February 2015


Do not remap until … (Cont.) What to do first… (Cont.) • Check instrumentation •

Fuel gas properties – LHVSEL = LHV raw, typical for site?, check specific gravity Acoustic sensors − PX36A > 25% different than PX36B? − Erratic output for either PX36 A or B?

•

Pressure Sensors

•

−

−

PS3 integrity very important − Water in lines? − Leaks in sensing tubes − Differences between sensors Fuel gas pressure (GP) sensors – difference between channel A vs. B?

Check other items

• • • • •

WFNOZZTOTFF parameters (requires trend data) 10% change at high power? Is inlet gas pressure significantly different from where last mapped? Verify proper operation of variable geometry (VIGV & VSV systems) −

Measure actuator length during calibration to ensure 100% travel

Check engine hardware for leakages Calibrate CDP, Stage 8, and thrust balance valves WTUI Conference March, 2015 Users Conference for GE’s Distributed Power business| February 2015


Package housekeeping Maintaining package cleanliness contributes to your long term availability • Materials such as rags, plastic caps, tape, oil, dirt, and others can create unforeseen operational issues • Oil Leaks can create Environmental, Health, & Safety concerns since they can occur inside or outside the package Maintain a vigilance to signs of potential emerging leaks. Most are detected by evidence of oil vapor, mist, film, staining, liquid • Trend oil consumption Inspection of tubing, hoses, piping for leaks, loose clamps, binding, kinking, delamination, insulation distress (braiding, fire sleeve) at scheduled maintenance intervals and anytime that the package is entered • Correct these items if present PREVENTION is the key to increased availability



Filter maintenance • Filters play a major role in Package Efficiency and Reliability • Don’t wait for high differential pressures (DP) to drive inspection • Make inspections part of your site preventative maintenance per OEM recommended schedules − Know which filters your package contains and where they are located − Reference OEM documentation • Maintain spares for critical systems • Reference your OEM Package Manual for additional information • Typical filters include: Air Filters: Primary & Secondary Mineral Lube Oil Demister Filter Turbine Lube Oil Filter FOD Sock Gas Fuel Filter SMEC System Filter Air/Oil Separator Filters

Generator Lube Oil Filter Hydraulic Lube Oil Filter Engine Hydraulic Pump Filter Jacking Oil Pump Filter Liquid Fuel Filter Accessory Skids Fan Filters



Enclosure fan maintenance Lubrication formula is dependent upon: • Fan RPM − specified on fan nameplate • Shaft Diameter: − Turbine Vent fan Shafts are 3 15/16” • Fan installation: − Vertical − Divide lubrication interval by 1/2 for vertical installations • Environment: − Divide lubrication interval by 1/3 for Heavy duty/High ambient Temp/ High moisture conditions. TCF Aerovent suggests the use of Plastilube #2 grease for heavy duty operation locations.

•



Enclosure fan maintenance Belt Tension: For Belt Driven Fans • •

Proper belt tension is important to fan operation and component life. Belt tension should be checked at installation and at every 100 hours for 300 hours to ensure proper tension.

•

•

Tension and physical condition of the belt should be checked at every fan lubrication interval. The belt should be taut, allowing slight deflection when both sides are squeezed between thumb and fore finger. The belt should snap back into position when released.

Bent fan shaft and over stressed bearings resulting from over tensioned belt

Procedures for adjusting belt tension are located in IM-100 (Installation manual provided by TCF Aerovent with every fan shipped). IM-100 can also be located at http://www.aerovent.com/aerovent/literature.asp •



Instrumentation maintenance and replacement Periodic maintenance • Calibrate instrumentation per OEM recommendations –

Calibration only during troubleshooting is not adequate

−

Contact GE if alternate instrumentation used

Replacement • Ensure instrument meets GE recommendations • Impacts safety and reliability • Example: LM2500 PS3 Transmitter − − − −

Response time 2 milliseconds Stall detection impaired if response time slower Failure to detect stall could result in engine damage Service Letters • •

LM1600-IND-07-001, LM2500-IND-07-003 LM5000-IND-07-002, LM6000-IND-07-002



Water ingress on external cabinets The accumulation of water and/or moisture inside cubicles and junction boxes has the potential to cause to equipment damage and unit trips. Cubicles and junction boxes exposed to weather should be periodically checked for the following: •

Check that cabinets are properly sealed

•

Eliminate possible source of water ingress, replace/repair seals

•

Verify that anti-condensation heaters are operating and sized properly, where applicable

Bulletins (Alert) •

Product Bulletin-LM2500-IND-0164

•

Product Bulletin-LM6000-IND-0215



Lube system chip detectors •

Electronic Chip Detectors provide early warning of possible bearing distress

•

Any indication should be immediately investigated

•

Chip detection may or may not imply distress

•

Follow trouble shooting procedure per your OEM Operation and Maintenance (O&M) manual

•

Action on Chip Detector Alarm −

Shut down Engine

−

Remove Detector - Assess acceptability of deposits per Operation and Maintenance manual

−

If acceptable, clean detector and return to service

O&M Criteria

Not Acceptable



Lube system chip detectors Trouble shooting steps • Remove scavenge screens • Examine material in lube screens and chip detectors −

Visual inspection or laboratory analysis − − −

−

If material is identified as any below, place engine “on-watch” − Preformed packing, O-ring, Gasket, Safety wire, Oil coke, Machining chip, Seal rub material If material is identified as M50 bearing material, replace components and/or engine per O&M manual If material cannot be identified: − Place engine “on watch” − Submit material for laboratory analysis

Engine “On-watch” Procedure: − −

Check and clean detectors daily Monitor lube oil temperatures and vibration levels



Supporting material

HP recoup orifice selection worksheet updates


DLE

  

O&M manuals updated via Interim Change Notice (ICNs)

Embed Excel worksheets



Bearings & sump materials COMPONENT

MATERIAL

Applicable to: SAC Base  Plus  +G4  MAGN

BEARINGS (X13) BEARING CAGES HORIZ & RAD DRIVE SHAFT GEARS (X8)

M50 STEEL BRONZE 4350 STEEL AMS 6265 ( 9310 STEEL)

Y N Y Y

SILVER CHROME (REPAIR) CHROME (REPAIR)

INLET GEARBOX (A SUMP)

BEARINGS (X3) BEARING CAGES BEVEL GEARS (X2) HORIZONTAL DRIVE SHAFT HPCR SPLINED ADAPTER

M50 STEEL AMS 4616 BRONZE AMS 6265 (9310 STEEL) AMS 6381 (4140 STEEL) AMS 6381 (4140 STEEL)

Y N Y Y Y

SILVER CHROME (REPAIR) CHROME (REPAIR) CHROME (REPAIR)

3R BEARING 3R CAGE ROTATING SEAL STATIONARY SEAL

M50 STEEL AMS 6414 (4340 STEEL) AMS 5643 (17-4 PH STAINLESS STEEL) AMS 5643 (17-4 PH STAINLESS STEEL)

Y Y Y Y

B SUMP

4R BEARING 4R CAGE 4B BEARING 4B CAGE ROTATING SEALS STATIONARY SEALS

M50 STEEL AMS 6414 (4340 STEEL) M50 STEEL AMS 6414 (4340 STEEL) AMS 5643 (17-4 PH STAINLESS STEEL) AMS 5643 (17-4 PH STAINLESS STEEL)

Y Y Y Y Y Y

SILVER SILVER NICKEL GRAPHITE

C SUMP

5R BEARING 5R CAGE 6R BEARING 6R CAGE ROTATING SEALS STATIONARY SEALS

M50 STEEL AMS 6414 (4340 STEEL) M50 STEEL AMS4616 BRONZE/AMS6414 (4340 STEEL) AMS 5643 (17-4 PH STAINLESS STEEL) AMS 5643 (17-4 PH STAINLESS STEEL)

Y Y Y N/Y Y Y


D SUMP

7R BEARING 7R CAGE 7B BEARING 7B CAGE ROTATING SEALS STATIONARY SEALS

M50 STEEL AMS4616 BRONZE/AMS6414 (4340 STEEL) M50 STEEL AMS4616 BRONZE/AMS6414 (4340 STEEL) AMS 5643 (17-4 PH STAINLESS STEEL) AMS 5643 (17-4 PH STAINLESS STEEL)

Y N/Y Y N/Y Y Y



  

COATING/PLATING

TRANSFER/ ACCESSORY GEARBOX

A SUMP

DLE

SILVER TEFLON/Metco 601


Fuel nozzles/T54 probes configuration

Applicable to: SAC Base  Plus +G4

DLE



Legend

Aft Looking Forward

##

Fuel Nozzle Number

##

T/C Number

3 nozzles in counter-clockwise direction affect T/C reading, Ex: Nozz. 7, 8 & 9 affect T/C #4 Reading



Fuel nozzles/T54 probes configuration


DLE

  

Legend

Aft Looking Forward

##

Fuel Nozzle Number

##

T/C Number

3 or 5 nozzles in counter-clockwise direction affect T/C reading, Ex: Nozz. 7, 8 & 9 affect T/C #3 Reading



910M29 configuration combustors G45

Baseline - PC/GB Model

G57

Baseline - PE/GE Model

G59

PC/GB Model - L605 Inserts

G62

PE/GE Model

G63

PE/GE Model - L605 Inserts

G67

PE/GE Model/2500+ TBC Coatings, LM2500/+ Dry

G73

PC/GB/PE/GE/PH Model - Dry/Steam Inject Naphtha/Water, Liquid/Water/No TBC


DLE

Gas Water/Dual Water

G69

PE/PC Model - Water Injection No L605 Inserts

G71

PE/PC Model - Water Injection L605 Inserts

L43663G01

PE/PC Model -Water Injection - With Gas/Water SER - Extended Venturis

G77

PE/PC Model -Water Injection - With Gas/Water Extended Venturis, LM2500/+ Wet (Productionized version of L43663G01)

G79

PE/PC Models - Water Injection Short Venturis DVM Coating on Dome, Bare Liners Cut Back Rivet Band - LM2500 Wet

G84

LM2500+/G4 Dual Fuel/Water Large Bore Venturis, DVM/TBC Coating Regular Rivet Band

G88

PE/PC Models - Water Injection Short Venturis DVM Coating on Dome, Bare Liners Cut Back Rivet Band - LM2500 Wet Large Eyelet Cowl

L38557G01

TBC Applied to G73, Lm2500/+ Dry

G75

PE/GE/PH Model Dual/Steam Large Bore Venturis

G78

LM2500/+ Dual/Steam, TBC Coating Large Bore Venturis

G83

LM2500+ G4 Dry Gas, Large Bore Venturis TBC on Dome & Liners

G86

PE/GE Model/2500+ TBC Coatings, LM2500/+ Dry Large Eyelet Cowl

G87

PC/GB/PE/GE/PH Model - Dry/Steam Inject Naphtha/Water, Liquid/Water/No TBC Large Eyelet Cowl



LM2500/+/+G4 SAC combustor Where-used-guide LM2500 SAC

LM2500+ SAC

Gas/Liq/DF Gas/DF Gas/Liq Liq/Water Water ST Dry G67





Prime

Prime

Gas/Liq/DF Gas/DF Gas/Liq ST Dry Water Prime

Prime

DF/ST

Gas/Liq/DF Gas/DF Dry Water

Prime

Notes TBC

No TBC



G77

Large Bore Swirlers Long Venturis Small Bore Large Bore Swirlers



G78

Prime

G79

Prime

Prime

DVM on Dome



G83 G84

Prime











L43663G01, G02, G03



Prime











G87

Prime

Prime

Prime

Prime

Prime

Large Bore Swirlers Large Bore Swirlers



G73 w/TBC

Prime

Long Venturis Small Bore G67 w/large eyelet G73 w/large eyelet



G86

G88

LM2500+G4 SAC



G75

L38557G01

DLE



G71 G73



DF/ST


G79 w/large eyelet

Prime



LM2500/+/+G4 SAC fuel nozzle configurations Previous Fuel Nozzle Configurations


DLE

Recommended/New Fuel Nozzle Configurations

Fuel Nozzle

Fuel Nozzle

Kit Reference

L21045P09 L31810G01

L21045P11 L31810G04 L31810G05 L31810G06

NEW/REPAIR NEW/REPAIR MEDIUM BTU LARGE TIP

682L310G01 682L310G11/G33

L31048P10 L31048P12 L31809P04

L31048P14 L31048P15 L31809P08

NEW/REPAIR NEW/REPAIR NEW/REPAIR

682L310G07 682L310G07 682L310G13/G34

L31421P07 L31421P09 L31809P01 L31809P03

L47465P07 L31421P10 L47465P02 L47465P03 L31809P05/7 L31809P10 L31809P14 L31809P12

REPAIR NEW/REPAIR REPAIR REPAIR NEW INCREASED GAS FLOW AREA LARGE TIP LARGE TIP/MEDIUM BTU

682L310G05/G15/G24 682L310G05/G15/G24 682L310G12/G22/G23 682L310G12/G22/G23 682L310G12/G22/G23 682L310G26/G27/G29/G32

L31809P09 L31809P11 L31809P13

NEW INCREASED GAS FLOW AREA LARGE TIP

682L525G01 682L525G01

L31805G09 L31805G08

NEW/REPAIR LOW BTU

682L400G04 682L400G01

L31957G03

NEW/REPAIR

682L400G12

L21045P12 L31810G03

NEW/REPAIR NEW/REPAIR

682L310G10 682L310G14

L47449P01

NEW/REPAIR

682L525G14/G15/G16/G17 G18/G19/G20/G21

9016M58P06

NEW

L38631P01 L31809P12 L31809P13 L38784P02 L61065P01 L31810G06 L61766P03

DUAL WITH WATER DUAL FUEL WATER/NO NOX DUAL FUEL DRY LOW BTU/WATER MEDIUM BTU DUAL GAS ONLY COKE OVEN GAS

GAS ONLY

GAS WATER

DUAL WATER - LM2500

DUAL WATER - LM2500+

GAS STEAM L31805G05 L31805G07 GAS/STEAM ON BOARD PREMIX L31957G02 GAS/STEAM OFF ENGINE PREMIX L21045P10 L31810G02 DUAL/STEAM ON BOARD PREMIX

LIQUID FUEL ONLY LM2500+G4

LM2500+/+G4


682L990G01 682L525G35/G40 682L525G34/G39 738L210G01 738L274G01/G02/G03/G04 682L995G01/G02


LM2500/+/+G4 DLE combustor configuration LM2500 L47614 G03

LM2500+ L47614 G03


DLE

  

LM2500+G4 L38640G03

G04

Cooling Changes

G04

Cooling Changes

L38640G04

Manufacturing Changes

G07

Extended Liners

G07

Extended Liners

L38640G05

Brazed Heat Shields

G09

Liner Material Change

G09

Changed Liner Material

G10

Fabricated Liners/Sheetmetal Cowl

G10

Fabricated Liners/Sheetmetal Cowl

G11

HS188 Liners/Dome Design Change

G11

HS188 Liners/Dome Design Change

G13, G14, G15

Repair Configurations Old Configs Repair to Upgraded Cinfigs.

G12

Uprate Config / HS188 Liners

G16

HA 230 Liners

G16

Non-Uprate / HA230 Liners

G17

Uprate / HA230 Liners

G18

Cut Back "B" Heat Shield - Make from G11

G18

Cut Back "B" Heat Shield Make from G11

G20

Cut Back "B" Heat Shield - Make from G10

G20

Cut Back "B" Heat Shield Make from G10

G21

Cut Back "B" Heat Shield

G22

Cast Domeplate/Cut Back "B"

G22

Non-Uprate Cast Domeplate/Cut Back "B"

G23

LM2000/LM2500 Cast Domeplate

G23

Uprate Cast Domeplate

L38640G04, G05

15 PPM - LM2500

G24

Nox Improvement



LM2500/+/+G4 pre-mixers & +G4 DLE combustor Part Number

Nomenclature


DLE

  

Used with Combustor P/N

Used On

L38362P03

NOZZLE,FUEL-3 CUP

LM2500+ G4 DLE

L38640G03, G04, G05

L38363P03

NOZZLE,FUEL-2 CUP

LM2500+ G4 DLE

L38640G03, G04, G05

L38107P03

NOZZLE,FUEL 3 CUP

LM2500+ G4 Dual Fuel DLE

L38640G03, G04, G05

L38145P03

NOZZLE,FUEL 2 CUP

LM2500+ G4 Dual Fuel DLE

L38640G03, G04, G05

L38087P01 L38087P02 L47197P06 L38107P02 L38145P01

NOZZLE,FUEL 3 CUP NOZZLE,FUEL 3 CUP NOZZLE,FUEL-2 CUP NOZZLE,FUEL 3 CUP NOZZLE,FUEL-2 CUP

LM2500+ LM2500+ LM2500+ LM2500+ LM2500+

L47614G12, G17, G23, G24 L47614G12, G17, G23, G24 L47614G12, G17, G23, G24

L47197P04 L47197P05 L47198P03 L47198P02 L38111P01 L38112P01 L38107P01 L38145P02 L61305P01 L61306P01

NOZZLE,FUEL-2 CUP NOZZLE,FUEL-2 CUP NOZZLE,FUEL-3 CUP NOZZLE,FUEL-3 CUP NOZZLE,FUEL-3 CUP NOZZLE,FUEL-2 CUP NOZZLE,FUEL 3 CUP NOZZLE,FUEL 2 CUP NOZZLE,FUEL 2 CUP NOZZLE,FUEL 3 CUP

LM2500+ DLE Pre-Uprate & LM2500 Base DLE - Alternate LM2500+ DLE Pre-Uprate & LM2500 Base DLE LM2500 Base DLE - Original Configuration LM2500 Base DLE & LM2500+ Pre-Uprate - Superceded Used On ESN 671-167 - Sup by L47198P03 Used On ESN 671-167 - Sup by L47197P05 LM2500 Base Dual Fuel DLE LM2500 Base Dual Fuel DLE LM2500 Base Dual Fuel DLE - 15 PPM LM2500 Base Dual Fuel DLE - 15 PPM

L47614G11, L47614G11, L38640G04, L38640G04,

L38100P01 L38101P01

NOZZLE,FUEL 2 CUP NOZZLE,FUEL 3 CUP

LM2000 DLE LM2000 DLE

L47614G23 L47614G23

DLE Uprate - Alternate Config DLE Uprate (T48 = 1546 F) DLE Uprate Dual Fuel DLE Dual Fuel DLE

L47614G03,G04,G07,G09,G10,G11,G16,G18,G20 L47614G03,G04,G07,G09,G10,G11,G16,G18,G20 L47614G03,G04,G07,G09,G10,G11,G16,G18,G20, G23 L47614G03,G04,G07,G09,G10,G11,G16,G18,G20, G23


G13, G14, G15, G18, G19, G20, G21, G22, G23 G13, G14, G15, G18, G19, G20, G21, G22, G23 G05 G05


Hot section configuration


HPT Type

Component

Part Number

Configuration Status Production Field

Coating External

Internal Repairable

SST (PE/PH) SST (PE/PH) SST (PE/PH) SST (PE/PH) SST (PE) SST (PE) SST (PE) SST (PH) SST (PH) SST (PH) SST (PE/PH) SST (PE/PH)

Blade, Stg 1 Blade, Stg 1 Blade, Stg 2 Blade, Stg 2 Nozzle, Stg 1 Nozzle, Stg 1 Nozzle, Stg 1 Nozzle, Stg 1 Nozzle, Stg 1 Nozzle, Stg 1 Nozzle, Stg 2 Nozzle, Stg 2

L31424G28 L31424G34 L25645G14 L25645G17 9283M87G11/G12 9283M87G23/G24 9283M87G19/G20 9283M87G13/G14 9283M87G15/G16 9283M87G21/G22 L31395G05/G06 L31395G11/G12

Available Current Available Current Current N/A N/A N/A Current N/A Current N/A

Available Current Available Current Current Current (new) Current (rep) Current Current (new) Current (rep) Current Current (new)

PBC22 PtAl PBC22 PtAl Codep TBC/Codep TBC/Codep Codep TBC/Codep TBC/Codep Codep PtAl

Al Al Al Al N/A N/A N/A N/A N/A N/A N/A N/A

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

TST TST TST TST TST TST TST TST

Blade, Stg 1 Blade, Stg 1 Blade, Stg 1 Blade, Stg 2 Blade, Stg 2 Blade, Stg 2 Nozzle, Stg 1 Nozzle, Stg 2

L25747G03 L25747G10 9198M37G12 L24484G18 9198M39G06 9198M39G10 L24461G09/G10 L21306G09/G10

Superseded Current N/A Current N/A Current Current Current

Superseded Current Current Current Current Current Current Current

PBC22 PBC22 Codep PBC22 Codep Codep Codep Codep

None Al Al None N/A Al N/A N/A

No Yes Yes No No Yes Yes Yes

SST = Single Shank Turbine TST = Twin Shank Turbine

PtAl = Platinum Aluminide Al = Aluminide

DLE

  

TBC = Thermal Barrier Coat VPA = Vapor Plasma Aluminide



Hot section configuration


DLE

  

HPT Type

Component

Part Number

Configuration Status Production Field

Coating External

Internal Repairable

LM2500 DLE LM2500 DLE LM2500 DLE LM2500 DLE LM2500 DLE

Blade, Stg 1 Blade, Stg 2 Nozzle, Stg 1 Nozzle, Stg 2 Nozzle, Stg 2

L31424G34 L25645G17 L47237G05/G06 L31395G05/G06 L31395G11/G12

Current Current Current Current N/A

Current Current Current Current Current

PtAl PtAl VPA VPA PtAl

Al Al N/A N/A N/A

Yes Yes Yes Yes Yes

LM2500+ LM2500+ LM2500+ LM2500+ SAC LM2500+ DLE LM2500+

Blade, Stg 1 Blade, Stg 1 Blade, Stg 2 Nozzle, Stg 1 Nozzle, Stg 1 Nozzle, Stg 2

L47459G01 L47459G03 L47467G02 L47490G01/G02 L47237G05/G06 L47483G01/G02

Superseded Current Current Current Current N/A

Superseded Current Current Current Current Current

PtAl PtAl PtAl VPA VPA PtAl

Al Al Al N/A N/A N/A

Yes Yes Yes Yes Yes Yes

LM2500+ LM2500+ LM2500+ LM2500+ LM2500+ LM2500+ LM2500+

Blade, Stg 1 Blade, Stg 2 S1N - GG S1N - GT S1N - GG S1N - GT Nozzle, Stg 2

L38582P01 L47467G02 L38609G01/G02 L38609G03/G04 L38606G01/G02 L38606G03/G04 L38611G01/G02

Current Current Current Current Current Current Current

Current Current Current Current Current Current Current

PtAl PtAl TBC/PtAl TBC/PtAl TBC/PtAl TBC/PtAl PtAl

Al Al Al Al Al Al Al

Yes Yes Yes Yes Yes Yes Yes

G4 G4 G4 SAC G4 SAC G4 DLE G4 DLE G4

PtAl = Platinum Aluminide Al = Aluminide

TBC = Thermal Barrier Coat VPA = Vapor Plasma Aluminide



TMF assembly configuration, gas turbine models (PE/PH)



DLE

  


TMF assembly configuration, GG Models



DLE

  


LM2500+/G4 TMF assembly configuration GG or GT



DLE

  


Deionized water purity specification


DLE

  

Shall not contain particles larger than 20 microns absolute Impurity

Limit

Test Method

Total matter, ppm, max

5

ASTM D5907

Dissolved matter, ppm, max

3

ASTM 5907

PH

6.0 - 8.0

ASTM D1293

at 26 deg. C, max (1)

0.5 - 1.0

ASTM D1125

Sodium & Potassium, ppm, max

0.1

ASTM D4191 &

Conductivity, micromhos/cm

ASTM D4192 Silicon dioxide, ppm, max.

0.1

ASTM D859

Chlorides, ppm, max

0.5

ASTM D512

Sulfates, ppm, max.

0.5

ASTM D516

Notes: (1) pH and or conductivity shall be measured when water is free of carbon dioxide



Water wash


Recommended practices

DLE

  

• Crank/Soak (Offline) for best results • Online - used for extending Intervals between crank/soaks • Detergent quality specification - MID-TD-0000-5 – See O&M manual volume I, appendix A • Water quality specification - MID-TD-0000-4 – See O&M manual volume I, appendix A



Water wash


Recommended practices – continued

DLE

  

• Crank soak procedure - see O&M manual volume I, chapter 5 – Variations in soak time may be required to suit environment – Clean flame sensing sight glasses after rinse – Ensure pressure transducer piping is free of water – Ensure precautions for icing conditions are taken – Borescope to substantiate compressor cleanliness

• On-Line system available through GE Aero Services – Dozens of successful retrofit systems in service on LM2500’s – High pressure online wash system with demineralized water – Includes independent controls, heater, pumps, manifold, etc. – Can also be used as a high pressure offline wash system



Lube oil cleanliness SOAP analysis - Atomic absorption method Particle quantity ranges for monitoring (in PPM) Element Iron (Fe) Silver (Ag) Aluminum (Al) Chromium (Cr) Copper (Cu) Magnesium (Mg) Nickel (Ni) Silicon (Si) Titanium(Ti) Molybdenum (Mo) Lead (Pb) Tin (Sn) Zinz (Zn)

Normal 0-3 0-1 0-1 0-4 0-5 0-1 0-3 0 - 20 0-3 0-3 0-3 0 - 15 0 – 10

On Watch 4-7 2-4 2-4 5-7 6 - 10 2-4 4-6 21 - 36 4-6 4-6 4-6 16 - 22 11 – 17



DLE

  

Shutdown 8+ 5+ 5+ 8+ 11 + 5+ 7+ 37 + 7+ 7+ 7+ 23 + 18+ © 2015 General Electric Company – All rights reserved.

Lube oil cleanliness


SOAP Analysis – Atomic emission method – continued Particle quantity ranges for monitoring (in PPM) Element Iron (Fe) Silver (Ag) Aluminum (Al) Chromium (Cr) Copper (Cu) Magnesium (Mg) Nickel (Ni) Silicon (Si) Titanium(Ti) Molybdenum (Mo) Lead (Pb) Tin (Sn) Zinc (Zn)

Normal 0-8 0-3 0-3 0-6 0 - 12 0-6 0-5 0 - 25 0-5 0-5 0-2 0 - 20 0 –15

On Watch 9 - 13 4-6 4-6 7-9 13 - 19 7-9 6-8 26 - 64 6-8 6-8 3-4 21 - 39 16 – 22


DLE

  

Shutdown 14 + 7+ 7+ 10 + 20 + 10 + 9+ 65 + 9+ 9+ 5+ 40 + 23 + © 2015 General Electric Company – All rights reserved.

Lube oil cleanliness limits


Other limits

DLE

  

Particle size limits: Range (microns)

Count Limit (per 100 ml sample)

• 15 - 25

10,000

• 25 - 50

1,500

• 50 - 100

200

• 100

20

H2O Limit:

1,000 ppm

TAN Limit:

1.0 KOH/gm

Viscosity Limit:

- 10% to + 25% ref to new oil WTUI Conference March, 2015


Lube oil alarm condition Recommended response


DLE

  

• Alarm for an abnormal engine condition requires immediate shutdown of the engine, investigation, and corrective action • Reducing power to clear an alarm is not immediate corrective action • Continued operation in an alarm condition can result in significant damage



Lube oil alarm condition


DLE

  

O&M manual limits • 30°F increase at steady state - shutdown & investigate

Initial values in ECU • Alarm: 300°F • Shutdown: 340°F

All O&M manuals updated to recommend the following; Recommended Limits:

Alarm

Shutdown

Lube Scavenge

Baseline Baseline

Temperature

+20°F

+40°F

(11°C)

(22°C)

Lube Scavenge

Baseline Baseline

Filter ΔP

+100%

+150%



Operational Reliability Analysis Program (ORAP) Strategic Power Systems (SPS) provides R&A fleet data via ORAP It is a WIN/WIN program for Customers and GE Customers – Customer reports outage types and outage duration on a periodic basis via SPS software program, web, fax or data as currently captured – All participating customers have ability to benchmark their plants against fleet. Fleet data is anonymous General Electric – GE receives availability data and outage types which provides valuable information to launch investigations and corrective actions to enhance product performance

Source: ORAP®; All rights to Underlying Data Reserved: SPS® WTUI Conference March, 2015


Operational Reliability Analysis Program (ORAP) How to get started •

Fill out plant configuration questionnaire & provide to SPS – Contact information – Plant information (application, arrangement, ratings, duty cycle etc) – Unit information (fuel, starting) – Equipment definition (model, serial numbers) – Gas turbine, package information – Etc

•

Agree with SPS on data entry method – Manual data entry – Data entry suite (minimal fees associated)

See Base ORAP Reference Guide & Data Entry Suite Brochures WTUI Conference March, 2015


LM2500 engine models PREFIXES Base SAC Base DLE 1800/2000 Base SAC 1800/2000 Base DLE Plus SAC Plus DLE Plus G4 SAC Plus G4 DLE

GG 691 (GE) 671 (GJ) 688 (GS) 197 (GN) 635 (GK) 636 (GR) 677 (HA) 680 (HG) 676 (HB) 683 (HH)

GT (6 PK) 481 & 606 (PE/PD/PL/PC) 589 (PH) 672 (PJ) 995 (PS) 996 (PN) 557 (PK) 559 (PR) 679 (RC) 678 (RD)

GG/GT (HSPT)

641 (GV/PV) 642 (GY/PY) 677 (RA) 676 (RB)

Marine GT (6 PK) 560 (PI/PF) 495/565 (PM/PZ) 882/881 (RE/RF) -

Marine Prop System (6 PK) PS1/PS4 (SA/SB) PS5 (SC) -

MODEL NUMBER DESIGNATIONS 7 = GE Aviation Product; L = Non-flight; M = Mechanical Turbine 2500 Engine Family G Gas Generator (GG) P Gas Turbine (GT) or Power Turbine (PT) Out of Production A Base SAC (1971 Twin Shank HPT Blades) Out of Production B Base SAC (1978 Twin Shank HPT Blades) Out of Production C Base SAC (1979 Twin Shank HPT Blades) Out of Production D Base SAC (1984 Twin Shank HPT Blades) Special Rating Qty 2 E Base SAC (Intro Point 1985 Single Shank HPT Blades) Marine F Base SAC Marine - GE Module H Base SAC with Larger A4 and Smaller A5 Marine I Base SAC Marine - No GE Module J Base DLE K Plus SAC L Base SAC with Nominal A4 and Smaller A5 Marine M Plus SAC Marine - GE Module N 2000 DLE R Plus DLE S 2000 SAC V Plus SAC for HSPT Y Plus DLE for HSPT Marine Z Plus SAC Marine - No GE Module M Marinized HPT Blade Coating N Non Marinized HPT Blade Coating D Dual Fuel G Gas Fuel L Liquid Fuel A Nox Suppression And Power Enhancement With Steam B Nox Suppression With Water And Enhancement With Steam C Power Enhancement (only) With Steam D Dry Low Emissions NEW F Dry Low Emissions 15 PPM Nox S Nox Suppression With Steam W Nox Suppression With Water X Early Prior Designation For Models Equipped For Nox Suppression Using Either Water Or Steam H Gas Generator R Gas Turbine A Plus G4 SAC (HSPT) High Speed Power Turbine B Plus G4 DLE (HSPT) High Speed Power Turbine C Plus G4 SAC (6 Pack or 6 PK) D Plus G4 DLE (6 Pack or 6 PK) Marine E Plus G4 SAC Marine - No Module (882) Marine F Plus G4 SAC Marine - No Module (881) G Plus G4 SAC (OEM PT) Corrected H Plus G4 DLE (OEM PT) M Marinized HPT Blade Coating D Dual Fuel G Gas Fuel L Liquid Fuel D Dry Low Emissions S Nox Suppression With Steam W Nox Suppression With Water Marine S Marine Module Add ====> A Base SAC Marine - GE Single Door Module Add ====> B Base SAC Marine - GE Two Door Module Add ====> C Plus SAC Marine - GE Module Add ====> M Marinized HPT Blade Coating Add ====> L Liquid Fuel 7LM



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Imagination at work

LM2500 WTUI 2015

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