GE Marine Engines GEK 105162
PROPULSION GAS TURBINE OPERATING INSTRUCTIONS 7LM2500-PZ-MLG01 (RCCL) (P & O) 7LM2500-PZ-MLG02 (SNCM) 7LM2500-PZ-MLG03 (NEL) 7LM2500-PZ-MLG04 (TSL) The information (including technical data) contained in this document is the property of GE. It is disclosed in confidence and the technical data therein is exported under a United States Government license. Therefore, none of the information may be disclosed to other than the recipient, or used for purposes other than to render services to GE, without the express written authorization of GE. In addition, the technical data therein, and the direct product of the data, may not be diverted, transferred, re-exported or disclosed in any manner not provided for by the license without the prior written approval of the United States Government.
GE Marine Engines Mail Drop S-156 One Neumann Way PO Box 156301 Cincinnati, Ohio 45215-6301, USA
GE Marine Engines GEK 105162
PROPULSION GAS TURBINE OPERATING INSTRUCTIONS 7LM2500-PZ-MLG01 (RCCL) (P & O) 7LM2500-PZ-MLG02 (SNCM) 7LM2500-PZ-MLG03 (NEL) 7LM2500-PZ-MLG04 (TSL) The information (including technical data) contained in this document is the property of GE. It is disclosed in confidence and the technical data therein is exported under a United States Government license. Therefore, none of the information may be disclosed to other than the recipient, or used for purposes other than to render services to GE, without the express written authorization of GE. In addition, the technical data therein, and the direct product of the data, may not be diverted, transferred, re-exported or disclosed in any manner not provided for by the license without the prior written approval of the United States Government.
GE Marine Engines Mail Drop S-156 One Neumann Way PO Box 156301 Cincinnati, Ohio 45215-6301, USA
Original - 1 September 1999 Change 2 - 20 APRIL 2001
GEK 105162
List of Effective Pages Dates of issue for original and changed pages are: Original . . . 0 . . . 1 September 1999 Change . . . 1 . . . 21 March 2000 Change . . . 2 . . . 20 April 2001 Total number of pages in this manual is 74 consisting of the following: Page No. Title A i to v vi 1-1 1-2 1-3 1-4 to 1-5 1-6 to 1-7 1-8 1-9 to 15/(1-16 Blank) 2-1 2-2 2-3 2-4 2-5 to 2-7 2-8 to 2-9 2-10 to 2-11/(2-12 Blank) 3-1 to 3-2
A
Change 2
Change No. 2 2 0 2 2 0 2 0 2 1 0 2 0 2 0 0 2 0 0
Page No. 3-3 3-4 3-5/(3-6 Blank) 4-1 to 4-3 4-4 4-5 to 4-8 4-9 4-10 to 4-11 4-12 4-13 4-14 to 4-16 4-17 to 4-18 4-19 4-20 4-21 to 4-24 4-25 4-26 to 4-32
Change No. 2 0 2 0 1 0 2 0 1 2 1 0 1 2 0 2 0
GEK 105162
Table of Contents Page Chapter 1
Chapter 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2
REFERENCED PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-3
NOTES, CAUTIONS, AND WARNINGS . . . . . . . . . . . . . . . . . . . . .
1-1
1-4
CHANGES TO TECHNICAL MANUAL . . . . . . . . . . . . . . . . . . . . . .
1-2
1-5
EQUIPMENT POINTS OF REFERENCE . . . . . . . . . . . . . . . . . . . .
1-2
1-6
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-7
MEASUREMENT UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-8
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-13
1-8.1
Material Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-13
1-8.2
Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-13
1-8.3
Electrical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-13
1-8.4
Environmental Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-14
1-8.5
Gas Turbine Operational Hazards . . . . . . . . . . . . . . . . . . . . . . .
1-14
General System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
PACKAGE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7
Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2
SENSORS AND INDICATING SYSTEMS . . . . . . . . . . . . . . . . . . . .
3-1
2-3 Chapter 3
3-2.1
Gas Generator Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2.2
Power Turbine Speed Transducer . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2.3
Vibration Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
i
GEK 105162
Table of Contents - (Cont) Page 3-2.4
Pressure/ Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . .
3-2.4.1
Chapter 4
High Pressure Compressor Total Pressure Probe/Inlet Air Temperature . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2.4.2
HPC Discharge Temperature . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-2.4.3
Power Turbine Inlet Temperature . . . . . . . . . . . . . . . . . . .
3-4
3-2.4.4
Fuel Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3-2.4.5
Lube Supply and Scavenge Temperature . . . . . . . . . . . . .
3-4
3-2.4.6
Pressure Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3-2.5
Chip Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3-2.6
Variable-Geometry Position . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
Operation and Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
PURPOSE AND SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-2
SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-2.1 4-3
Gas Turbine Maintenance/Inspection Precautions . . . . . . . . . .
4-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4-3.1
Site Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4-3.2
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4-3.3
Equipment Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4-3.3.1
Inlet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4-3.3.2
Exhaust Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4-3.3.3
Electrical, Fluid, and System Interface Covers . . . . . . . . .
4-3
Gas Turbine Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
4-3.4
4-3.4.1
Lubricating Oil Requirements . . . . . . . . . . . . . . . . . . . . . .
4-3.4.1.1 4-3.4.1.2
4-4
Lubricating Oil Pressure Corrections . . . . . . . . . Lubricating Oil Supply Pressure at Pressure Tap vs. Gas Generator/Gas Turbine Speed . . . . .
4-4
4-3.4.2
Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
4-3.4.3
Liquid Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
4-3.4.4
Adjustment of Gas Turbine High Pressure Recoup Cavity Pressure Within Preferred Operating Range . . . .
4-9
Adjustment of Power Turbine Thrust Balance Cavity Pressure Within Preferred Operating Range . . . .
4-9
4-3.4.5
ii
3-1
4-9
GEK 105162
Table of Contents - (Cont) Page 4-3.5
Initial Prestart Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12
4-3.6
Initial Operational Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12
4-3.7
Verification Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18
GAS TURBINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18
4-4
4-4.1
Component Life/Repair Intervals. . . . . . . . . . . . . . . . . . . . . . . .
4-19
4-4.2
Prestart Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19
4-4.3
Motoring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20
4-4.4
Starting and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21
4-4.4.1
Normal Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . .
4-21
4-4.4.2
Hot Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22
Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22
4-4.5
4-4.5.1
Normal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22
4-4.5.2
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-23
4-4.5.3
Post-Shutdown Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-24
4-4.6
Starter Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-24
4-4.7
Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-24
4-4.7.1
Hot Restarts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-24
4-4.8
Windmilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-25
4-4.9
Records and Running Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-25
4-5
ABNORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26
4-6
GENERAL DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26
4-7
CONTROL ACTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26
4-7.1
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26
4-7.2
Power Cutback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26
4-7.3
Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-26
4-7.3.1
Normal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-27
4-7.3.2
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-27
4-7.3.3
Step Deceleration to IDLE/Shutdown . . . . . . . . . . . . . . . .
4-27
4-7.3.4
Slow Deceleration to IDLE/Shutdown . . . . . . . . . . . . . . . .
4-28
4-7.3.5
Aborted Start/Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-28
iii
GEK 105162
Table of Contents - (Cont) Page 4-8
OPERATOR ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8.1
4-29
4-8.1.1
Overtemperature During Starting . . . . . . . . . . . . . . . . . . .
4-29
4-8.1.2
Lubricating Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
4-29
4-8.1.3
High Speed Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-29
4-8.1.4
Restart Following High Power Trip . . . . . . . . . . . . . . . . . .
4-30
4-8.1.5
No Power Turbine Rotation . . . . . . . . . . . . . . . . . . . . . . . .
4-30
TEST NO. 1 AND NO. 2 FUEL SHUTDOWN VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-30
4-10
TEST POWER TURBINE OVERSPEED SWITCH . . . . . . . . . . . . .
4-31
4-11
TEST POWER TURBINE SPEED LIMITING SYSTEM . . . . . . . . .
4-32
4-9
iv
Special Gas Turbine Constraints . . . . . . . . . . . . . . . . . . . . . . . .
4-28
GEK 105162
List of Illustrations Figure 1-1 1-2 2-1 2-2 3-1 3-2 3-3 4-1 4-2 4-3 4-4 4-5
Page Publication Change Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propulsion Gas Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Propulsion Gas Turbine Input/Output Diagram . . . . . . . . . . . . . . . . Gas Generator Speed (NGG) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Turbine Speed (NPT) Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermocouple Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating Oil Pressure Correction for LM2500+ SAC Gas Turbines using Lubricating Oil, MIL-L-23699 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating Oil Pressure Correction for LM2500+ SAC Gas Turbines using Lubricating Oil, MIL-L-7808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LM2500+ SAC Gas Turbine Oil Supply Pressure at Pressure Tap vs. GG Speed using Lubricating Oil, MIL-L-7808 . . . . . . . . . . . . . . . . . . . . . . . . . LM2500+ SAC Gas Turbine Oil Supply Pressure at Pressure Tap vs. GG Speed using Lubricating Oil, MIL-L-23699 . . . . . . . . . . . . . . . . . . . . . . . . Transient Temperature Limits (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3 1-4 2-4 2-9 3-2 3-3 3-5 4-6 4-8 4-10 4-11 4-17
v
GEK 105162
List of Tables Table 1-1 1-2 1-3 1-4 1-5 2-1 2-2 2-3 2-4 2-5 2-6 4-1 4-2 4-3 4-4 4-5
vi
Page Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metric and SI Unit Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conversion Table - Fractions to Decimals . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propulsion Gas Turbine Service Requirements . . . . . . . . . . . . . . . . . . . . . . . . LM2500-PZ-MLG01/G02/G03/G04 Installation Drawings and Schematics . . LM2500-PZ-MLG01/G02/G03/G04 Reference Documents . . . . . . . . . . . . . . . Standard Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propulsion Gas Turbine Input Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Propulsion Gas Turbine Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating Oil Pressure Correction for LM2500+ SAC Gas Turbines using Lubricating Oil, MIL-L-23699 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating Oil Pressure Correction for LM2500+ SAC Gas Turbines using Lubricating Oil, MIL-L-7808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Operating Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limits and Operating Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protective Function Causes Requiring Resolution Prior to Restart or Motoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change 2
1-5 1-8 1-10 1-11 1-12 2-2 2-3 2-3 2-6 2-8 2-10 4-5 4-7 4-14 4-16 4-23
GEK 105162
Chapter 1 Introduction 1-1
GENERAL INFORMATION
This manual provides operating procedures and limits for the LM2500-PZ-MLG01/G02/ G03/G04 gas turbine (GT), designed and manufactured by GE Marine Engines, Cincinnati, Ohio 45215-6301, USA. Information in this manual is to be used by shipboard personnel assigned to the equipment. 1-2
REFERENCED PUBLICATIONS
This manual is one in a series of five technical manuals that contains data pertinent to the LM2500-PZ-MLG01/G02/G03/G04 GT. A description of the contents of the other manuals is as follows: •
•
•
GEK 105056 provides depot repair procedures for the LM2500+ Single Annular Combustor (SAC) GT and identifies component life cycle limits. GEK 105163 provides a physical and functional description of the LM2500+ SAC GT and components, troubleshooting procedures, systems schematics, wiring diagrams, and scheduled maintenance procedures for shipboard maintenance. GEK 105164 provides corrective maintenance tasks in work package format for accomplishing specified alignment/adjustment, inspection, repair, and component replacement procedures.
•
1-3
GEK 105165, Illustrated Parts Breakdown (IPB), identifies and lists parts for the LM2500+ SAC GT and ancillary equipment in IPB format. NOTES, CAUTIONS, AND WARNINGS
Notes, cautions, and warnings are found throughout this publication. It is important that the significance of each is thoroughly understood by user personnel. Their definitions are as follows: WARNING Warnings refer to procedures or practices that may result in injury or death if not followed correctly. CAUTION Cautions refer to procedures or practices that may damage or destroy equipment if not followed correctly. NOTE Notes highlight an essential procedure or a condition that requires emphasis.
Change 2
1-1
GEK 105162
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 marine manual holders at the time 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 List of Effective Pages for current change page applicability. Changes or additions deemed necessary for proper operation, maintenance, and safety improvements should be submitted to: GE Marine Engines Marine Service and Factory Technical Support Mail Drop S-156 One Neumann Way PO Box 156301 Cincinnati, Ohio 45215-6301, USA Sample form shown in figure 1-1 may be reproduced and used for this purpose.
1-2
1-5
EQUIPMENT POINTS OF REFERENCE
All GT references to left, right, forward, aft, and clock positions apply when viewing the gas turbine from aft (exhaust end) looking forward (figure 1-2). References do not relate to ship fore and aft directions or other ship points of reference. 1-6
GLOSSARY OF TERMS
Table 1-1 lists and defines the abbreviations most commonly used in this manual. 1-7
MEASUREMENT UNITS
Syste’me International d’Unite’s (SI) or metric system is being adopted throughout the world. For this reason, SI unit conversions are shown in tables 1-2, 1-3, and 1-4. Fractions and decimal equivalents are shown in table 1-5. 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 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.
GEK 105162
Figure 1-1. Publication Change Request Change 2
1-3
GEK 105162
Figure 1-2. Position Orientation
1-4
GEK 105162
Table 1-1. Abbreviations Abbreviation
Definition
Abbreviation
Definition
abs
Absolute
Dim
Dimension
AC
Alternating Current
-dPS3/dt
ALF
Aft Looking Forward
amp
Ampere
Negative Rate of Change of Compressor Discharge Static Pressure
Assy
Assembly
ECU
Electronic Control Unit
atm
Standard Atmosphere
EMU
b
Bar
Engine Maintenance Unit
b (beta)
Variable Stator Position
°F
Degrees Fahrenheit
FIR
bhp
Brake Horsepower
Full Indicator Reading
Blisk
Blade/Disk Combination
FMP
Fuel Manifold Pressure
Btu
British Thermal Unit
FOD
°C
Degrees Centigrade (Celsius)
Foreign Object Damage
ft
Foot or Feet
cc
Cubic Centimeter
ft2
Square Foot or Feet
CCW
Counterclockwise
ft3
Cubic Foot or Feet
CDP
Compressor Discharge Pressure
FWD
Forward
g
Gram
CFF
Compressor Front Frame
gal
Gallon
CG
Center of Gravity
GEK
GEAE Publication Identification Number
cm
Centimeter
GG
Gas Generator
cm2
Square Centimeters
GT
Gas Turbine
cm3
Cubic Centimeters
Hg
Mercury
CRF
Compressor Rear Frame
Horiz
Horizontal
CRFV
Compressor Rear Frame Flange Accelerometer
hp
Horsepower
HP
High Pressure
HPC
High Pressure Compressor
HPCR
High Pressure Compressor Rotor
CW
Clockwise
DC
Direct Current
Dia
Diameter
1-5
GEK 105162
Table 1-1. Abbreviations - (cont.) Abbreviation
Definition
Abbreviation
Definition
HPCS
High Pressure Compressor Stator
lb
Pound
lb/ft2
Pound per Square Foot
lb/sec
Pound per Second
LVDT
Linear Variable Differential Transformer
m
Meter
m3
Cubic Meter
mA
Milliampere
Max
Maximum
Min
Minimum
mm
Millimeter
mv
Millivolt
MW
Megawatt
HPRCP
High Pressure Recoup Cavity Pressure
HPT
High Pressure Turbine
HPTR
High Pressure Turbine Rotor
hr
Hour
Hz
Hertz
ID
Inside Diameter
IGB
Inlet Gearbox
IGHP
Isentropic Gas Horsepower
IGKW
Isentropic Gas Kilowatt
IGV
Inlet Guide Vane
N
Newton
in.
Inch
N·m
Newton-meter
in.2
Square Inch
NGG
Gas Generator Speed
in.3
Cubic Inch
No.
Number
IPB
Illustrated Parts Breakdown
NOx
Oxides of Nitrogen
NPT
Power Turbine Speed
J
Joules
OAT
kcal
Kilocalorie
Outside Air Temperature
kg
Kilogram
OD
Outside Diameter
kg cm
Kilogram-centimeter
OGV
Outlet Guide Vane
kg m
Kilogram-meter
oz
Ounce
kg/sec
Kilogram per Second
P0
kJ
Kilojoules
Gas Turbine Inlet Pressure
kPa
Kilopascal
P2
Compressor Inlet Total Pressure
kW
Kilowatt
Pa
Pascals
l
Liter
Pamb
Ambient Pressure
lpm
Liters per Minute
PCB
Printed Circuit Board
l/sec
Liters per Second
1-6
Change 2
GEK 105162
Table 1-1. Abbreviations - (cont.) Abbreviation
Definition
Abbreviation
Definition
PCR
Publications Change Request
T3
PN
Part Number
Compressor Discharge Temperature
ppm
Parts per Million
T5.4 (T48)
PS3
High Pressure Compressor Discharge Static Pressure
Power Turbine Inlet Temperature
Tamb
Ambient Temperature
TAN
Total Acid Number
TBP
To Be Provided
PT
Power Turbine
Temp
Temperature
PTB
Power Turbine Balance Piston Pressure
TGB
Transfer Gearbox
PT5.4 (PT48)
Power Turbine Inlet Total Pressure
theta 2
qt
Quart
rpm
Revolutions per Minute
RTD
Resistance Temperature Detector
Ratio of Measured Absolute Gas Turbine Inlet Absolute Temperature to Standard Day Absolute Temperature
TMF
Turbine Mid Frame
S/O
Shutoff
TRF
Turbine Rear Frame
SAC
Single Annular Combustor
TRFV
Turbine Rear Frame Flange Accelerometer
sec
Second
V
Volt
SG
Specific Gravity
VA
Volt-ampere
shp
Shaft Horsepower
Vac
SI
Metric System
Volts, Alternating Current
Surf
Surface
Vdc
Volts, Direct Current
SWP
Subordinate Work Package
VG
Variable-Geometry
VRMS
T/C
Thermocouple
Volts, Root Mean Square
T2
Compressor Inlet Total Temperature
vs.
Versus
VSV
Variable Stator Vane
W
Watt
WP
Work Package
Change 2
1-7
GEK 105162
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
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
1-8
Change 1
GEK 105162
Table 1-2. Metric and SI Unit Conversion Factors - (cont.) To Convert From
To
Multiply By
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
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
Pa
6894.76
lb/in.2
kPa
6.8948
1-9
GEK 105162
Table 1-2. Metric and SI Unit Conversion Factors - (cont.) To Convert From
To
Multiply By
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
oz/gal
g/l
7.49
psi
kPa
6.894757
qt
l
0.9463
U.S. horsepower
metric horsepower
1.014
U.S. horsepower
kW
0.7457
Table 1-3. Pressure Conversions
Bar (b)
Standard Atmosphere (atm)
Kilograms per square centimeter (kg/cm2)
Pounds per square inch (lb/in.2)
Pascals (Pa)
1.0
0.987
1.020
14.504
100,000
1.013
1.0
1.033
14.696
101,325
0.981
0.968
1.0
14.22
98,067
0.0689
0.068
0.0703
1.0
6,895
1-10
GEK 105162
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.
-60 to 60 °C -51 -46 -40 -34 -29 -23 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 -11.7 -11.1 -10.6 -10.0 - 9.4 - 8.9 - 8.3 - 7.8 - 7.2 - 6.7 - 6.1 - 5.6 - 5.0 - 4.4 - 3.9 - 3.3 - 2.8 - 2.2 - 1.7 - 1.1 - 0.6 0.0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6
-60 -50 -40 -30 -20 -10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Temperature Conversion Formulas Temperature (°C) = (Temperature °F - 32) ÷ 1.8 Temperature (°F) = (1.8 x Temperature °C) + 32 61 to 350 360 to 1050 1060 to 1750 1760 to 2450 2460 to 3000 °F °C °F °C °F °C °F °C °F °C -76 16.1 61 141.8 182 360 680 571 1060 1940 960 1760 3200 1349 2460 -58 16.7 62 143.6 188 370 698 577 1070 1958 966 1770 3218 1354 2470 -40 17.2 83 145.4 193 380 716 582 1080 1976 971 1780 3236 1360 2480 -22 17.8 64 147.2 199 390 734 588 1090 1994 977 1790 3254 1366 2490 -4 18.3 65 149.0 204 400 752 593 1100 2012 982 1800 3272 1371 2500 14 18.9 66 150.8 210 410 770 599 1110 2030 988 1810 3290 1377 2510 32 19.4 67 152.6 216 420 788 604 1120 2048 993 1820 3308 1382 2520 33.8 20.0 68 154.4 221 430 806 610 1130 2066 999 1830 3326 1388 2530 35.6 20.6 69 156.2 227 440 824 616 1140 2084 1004 1840 3344 1393 2540 37.4 21.1 70 158.0 232 450 842 621 1150 2102 1010 1850 3362 1399 2550 39.2 21.7 71 159.8 238 460 860 627 1160 2120 1016 1860 3380 1404 2560 41.0 22.2 72 161.6 243 470 878 632 1170 2138 1021 1870 3398 1410 2570 42.8 22.8 73 163.4 249 480 896 638 1180 2156 1027 1880 3416 1416 2580 44.6 23.3 74 165.2 254 490 914 643 1190 2174 1032 1890 3434 1421 2590 46.4 23.9 75 167.0 260 500 932 649 1200 2192 1038 1900 3452 1427 2600 48.2 24.4 76 168.8 266 510 950 654 1210 2210 1043 1910 3470 1432 2610 50.0 25.0 77 170.6 271 520 968 660 1220 2228 1049 1920 3488 1438 2620 51.8 25.6 78 172.4 277 530 986 666 1230 2246 1054 1930 3506 1443 2630 53.6 26.1 79 174.2 282 540 1004 671 1240 2264 1060 1940 3524 1449 2640 55.4 26.7 80 176.0 288 550 1022 677 1250 2282 1066 1950 3542 1454 2650 57.2 27.2 81 177.8 293 560 1040 682 1260 2300 1071 1960 3560 1460 2660 59.0 27.8 82 179.6 299 570 1058 688 1270 2318 1077 1970 3578 1466 2670 60.8 28.3 83 181.4 304 580 1076 693 1280 2336 1082 1980 3596 1471 2680 62.6 28.9 84 183.2 310 590 1094 699 1290 2354 1088 1990 3614 1477 2690 64.4 29.4 85 185.0 316 600 1112 704 1300 2372 1093 2000 3632 1482 2700 66.2 30.0 86 186.8 321 610 1130 710 1310 2390 1099 2010 3650 1488 2710 68.0 30.6 87 188.6 327 620 1148 716 1320 2408 1104 2020 3668 1493 2720 69.8 31.1 88 190.4 332 630 1166 721 1330 2426 1110 2030 3686 1499 2730 71.6 31.7 89 192.2 338 640 1184 727 1340 2444 1116 2040 3704 1504 2740 73.4 32.2 90 194.0 343 650 1202 732 1350 2462 1121 2050 3722 1510 2750 75.2 32.8 91 195.8 349 660 1220 738 1360 2480 1127 2060 3740 1516 2760 77.0 33.3 92 197.6 354 670 1238 743 1370 2498 1132 2070 3758 1521 2770 78.8 33.9 93 199.4 360 680 1256 749 1380 2516 1138 2080 3776 1527 2780 80.6 34.4 94 201.2 366 690 1274 754 1390 2534 1143 2090 3794 1532 2790 82.4 35.0 95 203.0 371 700 1292 760 1400 2552 1149 2100 3812 1538 2800 84.2 35.6 96 204.8 377 710 1310 766 1410 2570 1154 2110 3830 1543 2810 86.0 36.1 97 206.6 382 720 1328 771 1420 2588 1160 2120 3848 1549 2820 87.8 36.7 98 208.4 388 730 1346 777 1430 2606 1166 2130 3866 1554 2830 89.6 37.2 99 210.2 393 740 1364 782 1440 2624 1171 2140 3884 1560 2840 91.4 37.8 100 212.0 399 750 1382 788 1450 2642 1177 2150 3902 1566 2850 93.2 43 110 230 404 760 1400 793 1460 2660 1182 2160 3920 1571 2860 95.0 49 120 248 410 770 1418 799 1470 2678 1188 2170 3938 1577 2870 96.8 54 130 266 416 780 1436 804 1480 2696 1193 2180 3956 1582 2880 98.6 60 140 284 421 790 1454 810 1490 2714 1199 2190 3974 1588 2890 100.4 66 150 302 427 800 1472 816 1500 2732 1204 2200 3992 1593 2900 102.2 71 160 320 432 810 1490 821 1510 2750 1210 2210 4010 1599 2910 104.0 77 170 338 438 820 1508 827 1520 2768 1216 2220 4028 1604 2920 105.8 82 180 356 443 830 1526 832 1530 2786 1221 2230 4046 1610 2930 107.6 88 190 374 449 840 1544 838 1540 2804 1227 2240 4064 1616 2940 109.4 93 200 392 454 850 1562 843 1550 2822 1232 2250 4082 1621 2950 111.2 99 210 410 460 860 1580 849 1560 2840 1238 2260 4100 1627 2960 113.0 104 220 428 466 870 1598 854 1570 2858 1243 2270 4118 1632 2970 114.8 110 230 446 471 880 1616 860 1580 2876 1249 2280 4136 1638 2980 116.6 116 240 464 477 890 1634 866 1590 2894 1254 2290 4154 1643 2990 118.4 121 250 482 482 900 1652 871 1600 2912 1260 2300 4172 1649 3000 120.2 127 260 500 488 910 1670 877 1610 2930 1266 2310 4190 122.0 132 270 518 493 920 1688 882 1620 2948 1271 2320 4208 123.8 138 280 536 499 930 1706 888 1630 2966 1277 2330 4226 125.6 143 290 554 504 940 1724 893 1640 2984 1282 2340 4244 127.4 149 300 572 510 950 1742 899 1650 3002 1288 2350 4262 129.2 154 310 590 516 960 1760 904 1660 3020 1293 2360 4280 131.0 160 320 608 521 970 1778 910 1670 3038 1299 2370 4298 132.8 166 330 626 527 980 1796 916 1680 3056 1304 2380 4316 134.6 171 340 644 532 990 1814 921 1690 3074 1310 2390 4334 136.4 177 350 662 538 1000 1832 927 1700 3092 1316 2400 4352 138.2 543 1010 1850 932 1710 3110 1321 2410 4370 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
°F 4460 4478 4496 4514 4532 4550 4568 4586 4604 4622 4640 4658 4676 4694 4712 4730 4748 4766 4784 4802 4820 4838 4856 4874 4892 4910 4928 4946 4964 4982 5000 5018 5036 5054 5072 5090 5108 5126 5144 5162 5180 5198 5216 5234 5252 5270 5288 5306 5324 5342 5360 5378 5396 5414 5432
1-11
GEK 105162
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
0.4063
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
0.7813
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
0.1563
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
0.5313
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
0.9063
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
0.2813
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
0.6563
1
1.0000
43/64
0.6719
1-12
GEK 105162
1-8
SAFETY PRECAUTIONS
This manual provides safe procedures and processes for accomplishing operation of the LM2500+ SAC. It is important all warnings and cautions be clearly understood and observed by users of this manual. This paragraph describes general safety precautions 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 gas turbine operation. 1-8.1
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 eyes. If exposed, rinse eyes in an eye bath fountain immediately and report to a physician.
1-8.2
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. 1-8.3
Electrical Hazards WARNING
Use extreme care when working with electricity. Electricity can cause shock, burns, or death. Electrical power shall be off before connecting or disconnecting electrical connectors. Lethal output voltages are generated by ignition exciter. Do not energize exciter unless output connection is properly isolated. Be sure all leads are connected, plug is installed, and all personnel are cleared to at least 5 ft (2.0 m) before energizing exciter for firing plug. If exciter is removed, fire it only in isolation chamber of the tester.
1-13
GEK 105162
1-8.4
Environmental Hazards
•
The GT is a high speed machine. In the remote case of component failure, 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 rotating parts.
•
Starter rotating parts operate at a very high speed. Personnel should not be stationed in the plane of 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 inlet while engine is operating.
WARNING 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. 1-8.5
Gas Turbine Operational Hazards WARNING
Outside surfaces of GT are not insulated. Adequate precautions should be taken to prevent operating personnel from inadvertently coming in contact with hot surfaces. WARNING •
1-14
The LM2500+ SAC GT 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 105162
WARNING •
•
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 personnel are inside enclosure, all personnel should immediately exit enclosure to prevent ingestion of 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 disassembly of engine for cleaning. Explosive mixture sensing devices should be provided to sense any leakage of fuel (into the packager’s enclosure). These devices should shutdown GT if leakage is present. If this occurs, exercise caution, determine and correct the cause of leakage before continuing operation. Enclosure and surrounding area should also be properly ventilated to clear any explosive fumes prior to restarting. WARNING
•
When entering GT enclosure, the following requirements must be met:
•
GT must be shut down or limited to IDLE power.
•
Fire extinguishing system must be made inactive according to packager’s/customer’s procedures.
•
Secondary air to enclosure must be shut off. High secondary airflow may prevent opening or closing enclosure door.
•
Enclosure door should be kept open. If GT is operating, an observer should be stationed at enclosure door and confined space entry procedures must be followed.
•
Allow GT to cool down. Avoid contact with hot parts, and wear thermally insulated gloves as necessary. WARNING
•
Ear protection must be worn if GT is operating.
•
Do not remain in enclosure or in plane of rotation of starter when starting or motoring the GT.
•
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.
•
Lock out all controls and switches, if possible; otherwise, tag electrical switches, out of service, to prevent inadvertent activation. Tag engine operating controls, do not operate, to prevent starting during a desired shutdown condition.
1-15/(1-16 Blank)
GEK 105162
Chapter 2 General System Description 2-1
PURPOSE AND SCOPE
This chapter provides a general description of the LM2500+ Single Annular Combustor (SAC) gas turbine (GT) and basic design features, and standard and optional equipment. It also summarizes G01/G02/G03/G04 model configurations, and provides a brief summary of GT heritage. 2-2
GENERAL DESCRIPTION AND FEATURES
2-2.2 Standard Equipment and Features a. The GT comes fully assembled with the following standard equipment installed and tested at the factory: •
GG with 17-stage high pressure compressor (HPC), SAC combustor, and 2-stage high pressure turbine (HPT)
•
Six-stage PT
•
Inlet duct and centerbody
•
Transfer gearbox (TGB) assembly and inlet gearbox (IGB) assembly
•
TGB driven lube pump, scavenge pump, hydraulic pump, variable stator vane (VSV) servovalve, and air/oil separator
•
Variable geometry (VG) control system for the VSV system
•
Specified fuel system (nozzles and manifolds)
•
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
2-2.1 General Description The LM2500+ SAC GT operates as part of the ship’s main propulsion system. The GT may be connected mechanically to an electrical generator or to the ship’s reduction gear and electrically to the ship’s control panels. Refer to table 2-1 for a listing of GT service requirements. Control of the power train is accomplished through a buyer-provided electronic control monitoring system. The GT is a two-shaft GT consisting of a gas generator (GG), power turbine (PT), inlet duct, and centerbody. The GG exhaust drives the PT, which turns a shaft that supplies power to the ship’s drive system. The GT generates power and transmits power through a coupling shaft to the ship’s reduction gearbox and propeller shaft or waterjet or electrical generator for electric drive applications. Refer to table 2-2 for installation drawings and schematics and table 2-3 for reference documents. See figure 2-1.
Change 2
2-1
GEK 105162
Table 2-1. Propulsion Gas Turbine Service Requirements Parameter
Value/Range
Inlet Air Temp
-65° to 130°F (-53.9° to 54.4°C)
Fuel Shutoff Values
18-32 Vdc, 40 watts max at 29 Vdc
Fuel Temperature
ISO 8217-ISO-F-DMA (MGO) Shall be the greater of 20°F (-6.7°C) above wax point temperature or temperature to achieve required viscosity of maximum temperature 160°F (71.1°C) 6 centistrokes maximum - start 12 centistrokes maximum - operation
Viscosity
Lubricating Oil Supply Pressure
Hydraulic Starter Flow Pressure Inlet Differential Temperature Hydraulic Fluid Ambient Contamination Electrical Power Ignition Units
Gas Turbine Water-Wash Pressure Flow
2-2
MIL-L-7808 MIL-L-23699, NATO CODE 0-156 6 psig (41.4 kPa) minimum 4,500 < NGG < 8,000 15 psig (103.4 kPa) minimum NGG > 8,000 Max scavenge discharge temperature 300°F (148.9°C)
0-55 gpm (0-208.2 lpm) starting 0-22 gpm (0-83.3 lpm) low-speed motoring 0-5,300 psig (0.0-36,542.2 kPa) 0-4,200 psid (0.0-28,958.0 kPa) 32° to 200°F (0.0° to 93.3°C) -40° to 140°F (-40.0° to 60.0°C) Filtered to 25 microns absolute (10 microns nominal)
115 V, single phase, 50/60 Hz, in rush 350 Vac, in operation 120 Vac
75 psig (517.1 kPa) 15 gpm at 45 psig (56.8 lpm at 310.3 kPa)
GEK 105162
Table 2-2. LM2500-PZ-MLG01/G02/G03/G04 Installation Drawings and Schematics Description
Drawing No.
Description
Drawing No.
Gas Turbine Installation Drawing
L50101
Inlet Bellmouth and Centerbody
537L372
Liquid Fuel System Schematic
L50211
Hydraulic & Pneumatic Starter
682L531
Gas Turbine Lubrication System Schematic
L43811
Hydraulic Start System Schematic
L43632
Electrical System Schematic
L50210
Ignition System
682L511
Table 2-3. LM2500-PZ-MLG01/G02/G03/G04 Reference Documents Subject
Document No.
Subject
Document No.
Liquid Fuel Specification
MID-TD-0000-2
Cable Assembly Specification
M50TF1276 Class B
Compressor Cleaning Water Purity Specification
MID-TD-0000-4
Dual Channel Signal Conditioner
M50TF1921
Compressor Cleaning Liquid Detergent Specification
MID-TD-0000-5
Industrial Repair Manual
GEK 105056
Lubricating Oil
MID-TD-0000-6
Scheduled Maintenance Manual
GEK 105163
LM2500+ Steady State Performance Computer Program
G0166A with Card Pack 7NE
Corrective Maintenance Manual
GEK 105164
LM2500+ Control System Specification
M50TF3847
Illustrated Parts Breakdown Manual
GEK 105165
Low Noise Cable Specification
M50TF1756 Class C
LM2500+ Engine System Mass Elastic Data
MID-TD-250031
Change 2
2-3
GEK 105162
Figure 2-1. Propulsion Gas Turbine b. The GT is completely assembled and factory tested. All items listed in paragraph 2-2.2 are mounted on the GT, except 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. NOTE Scheduled maintenance procedures are to be performed at specified intervals, reference Scheduled Maintenance Manual GEK 105163.
2-4
c. The GT is designed to separate into major modules and structural units to provide maximum flexibility for maintenance programs. The GT can be disassembled into interchangeable modules which can then be individually replaced or repaired. d. The GT is constructed with high degree of accessibility. Detail features are specifically aimed at individual component replacements, most of which can be accomplished on an installed GT.
GEK 105162
e. Features of the GT include the following: •
•
•
•
•
Accessories/instrumentation externally mounted for ease of replacement
2-2.3 Standard Instrumentation The GT is equipped with the sensors shown in table 2-4. Pressure taps are provided at the following locations for packager-supplied sensors: •
Lube oil supply line (one location)
Individually replaceable compressor rotor blades
•
Lube oil scavenge return line (one location)
Individually replaceable compressor stator vanes
•
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 [PT48]) (one location on turbine mid frame (TMF)). Probe is engine-supplied but transducer is purchaser-supplied
Individually replaceable high pressure turbine rotor (HPTR) blades 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
•
High pressure (HP) recoup pressure (two available locations)
•
Approximately 40 different ports, specifically located to facilitate borescope inspection. Using borescope procedure, complete inspection of GG gas path can be accomplished with GT installed
•
Fuel manifold pressures
•
VSV hydraulic supply oil pressure (one location)
•
Hydraulic oil filter pressure differential (one location)
•
PT balance piston pressure port (one location on PT rear frame)
•
Eight individual PT inlet temperature T5.4 (T48) probes and two-piece harness (mounted on the TMF)
2-5
GEK 105162
Table 2-4. Standard Instrumentation Qty
Sensor Description
2
GG speed sensors, magnetic pickup type
1
PT speed transducer, dual output magnetic pickup/transformer type
8
PT inlet temperature (T5.4 [T48]) sensors, dual element thermocouple probes
1
GG mounted accelerometer
1
PT mounted accelerometer
6
GT oil supply and scavenge system temperature sensors
6
GG oil scavenge electrical chip detectors
1
GT oil supply pressure
2
HPC discharge pressure (PS3)
1
Pressure tap for any fuel manifold pressure
1
PT5.4 (PT48) PT inlet pressure
2
T3 sensor (T/C), dual element thermocouple probe
1
Redundant P2/T2 sensor, duplex resistance temperature detector (RTD)
2
VSV position provided by a linear variable differential transformer (LVDT) located on VSV actuator
1
PT thrust balance cavity pressure
Additional instrumentation requirements are described in Chapter 3.
2-6
GEK 105162
2-3
PACKAGE DESCRIPTION
The GT package is a complete system built around the LM2500+ SAC GG and 6-stage PT. The package provides the structure, interfaces, service connections, and controls necessary to operate the GT and to utilize the energy and/or shaft output. This package needs only to be installed in the ship 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, 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 system, if applicable
Tables 2-5 and 2-6 give the input and output functions of the GT.
2-7
GEK 105162
Table 2-5. Propulsion Gas Turbine Input Functions
Nomenclature
Function
Operating range/condition
Figure No.
Item No.
NOTE NOTE Models 7LM2500-PZ-MLG02/G03/G04 use one ignition exciter. Ignition exciters No. 1 and No. 2
Provide ignition for starting GT
Characteristics of power input to ignition unit shall be as follows: Voltage: 115 V ± 8 percent Frequency: 60 Hz or 50 Hz ± 5 percent Phase: Single Phase Current Draw: 350 VA inrush per unit 120 VA operating per unit
2-2
13
NOTE NOTE Model 7LM2500-PZ-MLG01 has a packager supplied starter. Hydraulic starter
Used to start or motor GT
Ship’s hydraulic system supplies pressure to hydraulic starter 55 gpm (208.2 lpm), 4,200 psid (28,958.0 kPa), 5,300 psig (36,542.2 kPa) max inlet
2-2
14
Fuel shutdown valves No. 1 and No. 2
Shuts off fuel to GT
Power to fuel shutdown valves from buyer control system: 18-32 Vdc, 40 W max at 29 Vdc (each valve)
2-2
3
VSV LVDT No. 1 and No. 2 excitation
Sinusoidal excitation of LVDT coils by purchaser control system
7.07 VRMS 3000 Hz ± 100 Hz 20 mA peak-to-peak
2-2
10
2-8
Change 2
GEK 105162
Figure 2-2. Typical Propulsion Gas Turbine Input/Output Diagram Change 2
2-9
GEK 105162
Table 2-6. Propulsion Gas Turbine Output Functions
Nomenclature
Function
Operating range/ condition
Figure No.
Item No.
PT speed (NPT) signal input, channels A and B (2 signals)
Each pickup provides signal proportional to PT speed
0-4,980 Hz; 0-3,600 rpm, 100 percent speed
2-2
1
0-75 psia (0.0-517.1 kPa)
2-2
2
PT inlet pressure range gas pressure (PT5.4 [PT48]) signal GT inlet air pressure (PT2) signal
Pressure range
0-16 psia (0.0-110.3 kPa)
2-2
4
GT fuel manifold pressure (FMP)
Fuel manifold pressure
0-1,500 psig (0.0-10,342.1 kPa)
2-2
5
GT lubrication supply pressure
Lubricating oil pressure
0-100 psig (0.0-689.5 kPa)
2-2
6
Lubricating oil scavenge temperature sensors
RTD provides resistance proportional to scavenge oil temperature in A-, B-, C-, and D-sumps, and transfer gearbox
84-178 ohms, -40° to 400°F (-40.0° to 204.4°C) 2 mA max
2-2
7
GG speed pickup (NGG)
Provides signal proportional to NGG
1 rpm = 0.78329 Hz output frequency 0-12,000 rpm 0-142 V peak-to-peak (sinusoidal)
2-2
8
GT compressor discharge static pressure (PS3 or CDP)
CDP (PS3)
0-360 psig (0.0-2,482.1 kPa)
2-2
9
2-10
GEK 105162
Table 2-6. Propulsion Gas Turbine Output Functions - (cont.)
Nomenclature
Function
Operating range/ condition
Figure No.
Item No.
PT inlet temperature (T5.4 [T48]) thermocouple
Provides signal proportional to T5.4 (T48)
-0.69 to 44.86 mV; 0° to 2000°F (-17.8° to 1,093.3°C)
2-2
2
GG vibration accelerometer
Provides signal proportional to GG vibration
40.55-42.13 mV/cm/sec (103-107 mV/in/sec) mean sensitivity at 75°F (23.9°C)
2-2
11
PT vibration accelerometer
Provides signal proportional to PT vibration
40.55-42.13 mV/cm/sec (103-107 mV/in/sec) mean sensitivity at 75°F (23.9°C)
2-2
12
2-11/(2-12 Blank)
GEK 105162
Chapter 3 Controls and Indicators 3-1
GENERAL
For ship-to-gas turbine (GT) control interface and indicators required for operation of the GT, refer to the applicable packager’s manual. 3-2
SENSORS AND INDICATING SYSTEMS
This paragraph describes the various enginemounted sensors and indicating systems required for normal operation of the LM2500+ Single Annular Combustor (SAC). 3-2.1 Gas Generator Speed Sensor The GT is equipped with two magnetic-type gas generator speed (NGG) sensors mounted in the transfer gearbox (TGB) section for sensing NGG. The speed signal is produced by sensing passing gear teeth frequency on a spur gear in the TGB. See figure 3-1. 3-2.2 Power Turbine Speed Transducer The power turbine (PT) is equipped with one dual output magnetic-type power turbine speed (NPT) transducer mounted in the turbine rear frame (TRF) for sensing PT rotor speed. The assembly operates in conjunction with a toothed gear attached to the PT rear shaft. As gear teeth pass poles of the transducer, AC voltage is generated. See figure 3-2.
3-2.3 Vibration Sensors The GT is equipped with two accelerometers, one on the compressor rear frame (CRF) and one on the TRF. The accelerometers provide protection against self-induced synchronous vibration. Each sensor is capable of monitoring vibration levels of both high and low rotor speeds. Each accelerometer sensor has an integral lead that is routed to one of the electrical panels. 3-2.4 Pressure/ Temperature Sensors 3-2.4.1
High Pressure Compressor Total Pressure Probe/Inlet Air Temperature
The GT is equipped with a dual purpose probe to measure high pressure compressor (HPC) inlet total pressure (P2) and HPC inlet total temperature (T2). The probe contains a dualelement resistance temperature detector (RTD). The probe is mounted on the compressor front frame (CFF). 3-2.4.2
HPC Discharge Temperature
Two HPC discharge temperature (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.
3-1
GEK 105162
Figure 3-1. Gas Generator Speed (NGG) Sensor 3-2
GEK 105162
Figure 3-2. Power Turbine Speed (NPT) Transducer Change 2
3-3
GEK 105162
3-2.4.3
Power Turbine Inlet Temperature
Eight separate, shielded chromel-alumel (type K) thermocouple probes are installed in the turbine mid frame (TMF). The dualelement power turbine inlet temperature (T5.4 [T48]) sensor has readout capability for each element via two cable harnesses. See figure 3-3. 3-2.4.4
Fuel Temperature Sensors
The gas generator (GG) is equipped with a single-element, chromel-alumel (type K) thermocouple probe mounted on the fuel manifold. 3-2.4.5
Pressure Parameters
The LM2500+ SAC includes provisions for measurement of the following pressure parameters:
3-4
Fuel pressure at liquid fuel manifold inlets
•
PT inlet pressure (PT5.4 [PT48]) (one location)
•
PT balance piston pressure (PTB) (one location)
The lubricating oil and fuel supply pressure indications can be used for condition monitoring or troubleshooting. PS3, Prcp, and PT5.4 (PT48) are vital to engine operation and are an integral part of the packager-supplied control system. Refer to the applicable packager’s manual for sensors, leads, and readout devices.
Lube Supply and Scavenge Temperature
Six dual-element platinum RTDs are provided as standard equipment on the engine for measurement of lubricating oil supply and scavenge oil temperatures. RTDs sense temperatures of bearing lubricating oil supply and scavenge oil from individual gearbox and sumps (TGB, A, B, C, D). Optional redundant RTDs may also be included. 3-2.4.6
•
NOTE •
All sensing lines for flowpath pressure measurement must include provision for preventing water accumulation in the line.
•
Line volume limits exist on the PS3 sensors.
3-2.5 Chip Detectors The GT is equipped with electrical/magnetic remote-reading chip detectors. The chip detectors are located in the lube and scavenge pump at the scavenge line connections for the TGB, B-, C-, and D-sumps.
•
Lubricating oil supply line (one location)
Each chip detector indicates chip collection when resistance across the detector drops below 100 ohms.
•
Lubricating oil scavenge return line (one location)
3-2.6 Variable-Geometry Position
•
HPC discharge static pressure (PS3) (two locations)
•
High pressure recoup pressure (Prcp) (two locations)
The position of the HPC variable stator vane (VSV) is provided to the control and monitoring systems by independent linear variable differential transformers (LVDTs). The two actuators in the VSV system are equipped with LVDTs.
GEK 105162
Figure 3-3. Thermocouple Schematic Change 2
3-5/(3-6 Blank)
GEK 105162
Chapter 4 Operation and Operating Parameters 4-1
PURPOSE AND SCOPE
This chapter covers safety, installation, prestartup inspections, and verification test procedures for the gas turbine (GT) following initial installation and/or subsequent removal and replacement of the GT or major components. This chapter also covers general operating procedures that are typical of any LM2500+ Single Annular Combustor (SAC) powered package. The following topics are directed at ensuring that operating, maintenance, and support personnel have a source of technical information associated with the GT and its operation as installed in an enclosure. This chapter provides the operator with specific requirements about air, oil, and fuel used during normal operation and is intended to ensure that the GT is operating in the environment and under conditions for which it was designed. The information may not provide for every variation in installation, equipment, or contingency to be found in conjunction with GT operation. Configuration and system procedures may vary from package to package and with the packager-supplied control system. Before operating the GT, operators should be thoroughly trained in both normal and abnormal (emergency) operations. They must also be trained on the control system action/reaction to these conditions. Additional information can be provided by the packager or by General Electric Marine Engines.
4-2
SAFETY
General safety precautions are defined in Chapter 1. The following safety considerations should be observed by operators and support personnel working on the GT: •
Outside surfaces of the engine are not insulated. Adequate precautions should be taken to prevent personnel from inadvertently contacting hot surfaces.
•
The GT is a source of considerable noise. It is necessary for personnel working on or in GT vicinity to wear proper ear protection equipment when the GT is operating.
•
The GT has high speed rotating components. 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 rotating parts.
•
Parts of the starter operate at a very high speed. To guard against the remote case of parts failure, personnel should not be stationed near the starter during start, motoring, or purge cycles.
4-1
GEK 105162
•
•
•
4-2
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 directly on engine casings is permissible. The use of chemical fire extinguishing media will require the disassembly of the GT for cleaning. Fire extinguishing media can be toxic or smothering. Care must be taken to ensure that all personnel are clear of enclosure prior to fire extinguisher system activation. Failure to comply may result in injury or death to personnel remaining inside enclosure.
•
Suitable explosive mixture sensing devices should be provided to sense the leakage of fuel and to shut down the GT 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 enclosure access doors and should clearly state the hazardous conditions that exist in the enclosure during operation above IDLE.
4-2.1 Gas Turbine Maintenance/ Inspection Precautions WARNING •
When entering the engine enclosure, the requirements listed below must be met.
•
The GT 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.
•
Secondary air to enclosure shall be shut off.
•
Enclosure door shall be kept open. If GT is operating, an observer shall be stationed at enclosure door.
•
Allow the GT to cool before entering enclosure. Avoid contact with hot parts; wear thermally insulated gloves if necessary.
•
Ear protection shall be worn if the GT is operating.
•
Do not remain in enclosure or in plane of rotation of starter when starting or motoring the GT.
•
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.
GEK 105162
WARNING •
•
4-3
Tag electrical switches Out of Service to preclude inadvertent activation. Tag GT operating controls Do Not Operate to prevent starting during a desired shutdown condition. Do not use GT piping, cables, instrumentation leads, or other external hardware as hand or footholds when performing maintenance. These hardware items are not designed to support loads other than those associated with GT operation. INSTALLATION
If not already installed, the GT should be installed according to the packager’s requirements and specifications. For specific details on GT installation procedures and tools, refer to, GEK 105164, work package (WP) 300 00, WP 301 00, WP 302 00, and WP 001 00 as well as the packager’s manual. 4-3.1 Site Information Refer to the applicable packager’s manuals and drawings for installation design details. 4-3.2 Installation Procedure NOTE •
•
Use new preformed packings, seals, or gaskets at all connections where required. Refer to the appropriate packager’s manual for mounting points, interface locations, and component weights.
b. Install starter onto transfer gearbox (TGB) per GEK 105164, WP 120 00, and configure the GT as required by the site and packager’s instructions. c. Install ignition leads per GEK 105164, WP 107 00. 4-3.3 Equipment Protection The GT has covers to protect various operational interfaces during shipping, handling, installation, and maintenance activity. Covers are provided and used to protect the GT from potential foreign object damage (FOD) caused by handling and objects such as dirt, weld beads, tools, rags, nuts, and bolts. 4-3.3.1
Inlet Cover
The GT is shipped with an inlet cover that should only be removed when the GT is installed in the package. This cover should be retained by the operator and installed for GT protection any time the inlet connection is broken. 4-3.3.2
Exhaust Cover
The GT is shipped with an exhaust cover which should be left in place until the GT is mated to its interface. This cover should be retained by the operator and installed any time the GT is disconnected. 4-3.3.3
Electrical, Fluid, and System Interface Covers
The GT is shipped with protective covers over all electrical, fluid, and system interfaces. These covers prevent handling damage (threads, pins, etc.) and fluid or system piping contamination.
a. Install and align GT per packager’s instructions.
4-3
GEK 105162
A supply of covers should be maintained by the operator for use during maintenance activities electrical leads, fluid piping, or system piping to be disconnected. 4-3.4 Gas Turbine Protection The LM2500+ SAC is designed to operate in a marine atmosphere for extended periods of time. However, the operator must follow certain basic procedures to enhance the GT operational capability. Monitoring the power turbine (PT) thrust balance cavity pressure is required because seal leakage can change with operation. Leakage may cause thrust balance cavity pressure to fall outside of the preferred operating range. Refer to GEK 105164, WP 428 00, to measure and adjust cavity pressure with GT installed. 4-3.4.1
Lubricating Oil Requirements
Lubricating oil is used to lubricate bearings, gears, and some splines. Lubricating oil is also used in the variable-geometry (VG) control actuation system. Lubricating oil must be temperature-controlled and kept clean per the following requirements: a. The requirements for GT lubricating oil are provided in GEK 105163, Appendix A4. b. Minimum temperature at start is 20°F (-6.7°C) for lubricating oil, MIL-L-23699, Type II, and -20°F (-28.9°C) for lubricating oil, 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 (60.0° 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). 4-4
Change 1
f. Mixing of different types (Type I vs. Type II) of lubricating oils is not allowed. Mixing of lubricating oil brands of the same type is acceptable. Topping off when changing lubricating oil brands of the same type is the preferred method, but indiscriminate changing is not recommended. CAUTION Failure to properly maintain a clean lubrication system could result in premature failure of the GT or components. g. Before initial motoring and starting the GT in a new installation or following work on the lubrication system, the lubricating oil conditioning and storage system and all of the various circuits should be flushed to ensure cleanliness. CAUTION Following this flushing, the system filter elements should be removed or replaced to avoid GT contamination. h. In the event of a failure during ship operation that involves the GT lubrication system, the complete system should be disconnected, drained, and cleaned as described in step g. This procedure should be followed if the GT is removed and replaced or repaired on-board. i. Lubricating oil should be filtered to 10 microns, nominal. 4-3.4.1.1
Lubricating Oil Pressure Corrections
Tables 4-1 and 4-2 and figures 4-1 and 4-2 provide corrections and limits for lubricating oil supply pressure.
GEK 105162
Table 4-1. Lubricating Oil Pressure Correction for LM2500+ SAC Gas Turbines using Lubricating Oil, MIL-L-23699 NOTE NOTE The following values are for corrections to 9,000 rpm gas generator speed (NGG) and 150°F (65.6°C) lubricating oil inlet temperature. Read oil pressure and temperature, then algebraically add the pressure additive as indicated for that particular rpm and oil temperature to the observed oil pressure. Corrected oil pressure limit is 45-55 psig (310.3-379.2 kPa). Oil Supply Temp °F (°C) 100 (37.8) 110 (43.3) 120 (48.9) 130 (54.4) 140 (60.0) 150 (65.6) 160 (71.1) 170 (76.7) 180 (82.2) 190 (87.8) 200 (93.3) 210 (98.9) 220 (104.4)
Gas Generator Speed (rpm) 8,000 - 7.74 - 3.52 - 0.02 + 2.91 + 5.82 + 8.60 +11.13 +13.35 +15.07 +16.53 +17.57 +18.40 +19.08
8,100
8,200
8,300
8,400
8,500
8,600
8,700
8,800
8,900
9,000
- 8.93 - 4.64 - 1.10 + 1.93 + 4.92 + 7.77 +10.34 +12.61 +14.33 +15.80 +16.84 +17.67 +18.36
-10.14 - 5.76 - 2.19 + 0.94 + 4.01 + 6.93 + 9.55 +11.87 +13.58 +15.06 +16.10 +16.93 +17.64
-11.35 - 6.89 - 3.30 - 0.06 + 3.11 + 6.09 + 8.75 +11.12 +12.83 +14.31 +15.35 +16.18 +16.90
-12.58 - 8.03 - 4.42 - 1.07 + 2.19 + 5.24 + 7.95 +10.33 +12.07 +13.55 +14.60 +15.42 +16.16
-13.81 - 9.18 - 5.54 - 2.09 + 1.27 + 4.38 + 7.14 + 9.52 +11.31 +12.77 +13.83 +14.65 +15.41
-15.05 -10.34 - 6.64 - 3.12 + 0.33 + 3.52 + 6.32 + 8.71 +10.54 +11.98 +13.06 +13.88 +14.65
-16.31 -11.51 - 7.75 - 4.14 - 0.60 + 2.65 + 5.50 + 7.90 + 9.77 +11.18 +12.27 +13.10 +13.89
-17.57 -12.69 - 8.86 - 5.16 - 1.55 + 1.77 + 4.67 + 7.07 + 8.99 +10.38 +11.46 +12.31 +13.12
-18.85 -13.88 - 9.98 - 6.19 - 2.50 + 0.89 + 3.84 + 6.24 + 8.18 + 9.56 +10.65 +11.51 +12.34
-20.14 -15.08 -11.11 - 7.23 - 3.46 0 +3.00 +5.40 +7.36 +8.74 +9.83 +10.71 +11.55
Oil Supply Temp
Gas Generator Speed (rpm)
°F (°C)
9,100
9,200
9,300
9,400
9,500
9,600
9,700
9,800
9,900
10,000
100 (37.8) 110 (43.3) 120 (48.9) 130 (54.4) 140 (60.0) 150 (65.6) 160 (71.1) 170 (76.7) 180 (82.2) 190 (87.8) 200 (93.3) 210 (98.9) 220 (104.4)
-12.43 -16.30 -12.25 - 8.28 - 4.43 - 0.09 + 2.16 + 4.55 + 6.53 + 7.91 + 9.00 + 9.90 +10.76
-22.74 -17.52 -13.39 - 9.33 - 5.39 - 1.81 + 1.31 + 3.70 + 5.69 + 7.08 + 8.16 + 9.08 + 9.95
-24.05 -18.74 -14.55 -10.38 - 6.36 - 2.72 - 0.46 + 2.84 + 4.84 + 6.23 + 7.31 + 8.25 + 9.14
-25.37 -19.99 -15.17 -11.43 - 7.33 - 3.64 - 0.40 + 1.99 + 3.99 + 5.38 + 6.45 + 7.42 + 8.33
-26.70 -21.27 -16.87 -12.49 - 8.31 - 4.56 - 1.27 + 1.12 + 3.13 + 4.52 + 5.59 + 6.57 + 7.50
-28.04 -22.56 -18.05 -13.56 - 9.30 - 5.49 - 2.16 + 0.25 + 2.24 + 3.66 + 4.72 + 5.72 + 6.67
-29.39 -23.86 -19.23 -14.64 -10.29 - 6.53 - 3.09 - 0.62 + 1.34 + 2.77 + 3.85 + 4.86 + 5.83
-30.76 -25.18 -20.42 -15.72 -11.29 - 7.37 - 4.02 - 1.05 + 0.43 + 1.86 + 2.96 + 4.00 + 4.98
-32.13 -26.51 -21.62 -16.81 -12.30 - 8.32 - 4.96 - 2.39 - 0.48 + 0.95 + 2.07 + 3.12 + 4.13
-33.50 -27.85 -22.83 -17.91 -13.31 - 9.27 - 5.91 - 3.28 - 1.41 + 0.03 + 1.17 + 2.24 + 3.26
NOTE:
Oil MIL-L-23699
Example:
Observed NGG 8,700 rpm Observed Oil Pressure 56 psig (386.1 kPa) Oil Temperature 130°F (54.4°C) Pressure Additive -4.14 psig (28.5 kPa) Corrected Pressure 56 - 4.14 = 51.86 psig (357.6 kPa)
4-5
GEK 105162
Figure 4-1. Lubricating Oil Pressure Correction for LM2500+ SAC Gas Turbines using Lubricating Oil, MIL-L-23699 4-6
GEK 105162
Table 4-2. Lubricating Oil Pressure Correction for LM2500+ SAC Gas Turbines using Lubricating Oil, MIL-L-7808 NOTE NOTE The following values are for corrections to 9,000 rpm NGG and 150°F (65.6°C) lubricating oil inlet temperature. Read oil pressure and temperature then algebraically add the pressure additive as indicated for that particular rpm and oil temperature to the observed oil pressure. Corrected oil pressure limit is 37-45 psig (255.1-310.3 kPa). Oil Supply Temp
Gas Generator Speed (rpm)
°F (°C)
8,000
8,100
8,200
8,300
8,400
8,500
8,600
8,700
8,800
8,900
9,000
100 (37.8) 110 (43.3) 120 (48.9) 130 (54.4) 140 (60.0) 150 (65.6) 160 (71.1) 170 (76.7) 180 (82.2) 190 (87.8) 200 (93.3) 210 (98.9) 220 (104.4)
- 4.69 - 1.72 + 1.08 + 3.59 + 5.79 + 7.41 + 8.79 + 9.77 +10.55 +11.23 +11.89 +12.52 +13.08
- 5.36 - 2.58 - 0.29 + 2.84 + 5.08 + 6.70 + 8.09 + 9.07 + 9.85 +10.55 +11.22 +11.87 +12.43
- 6.58 - 3.45 - 0.51 + 2.08 + 4.34 + 6.00 + 7.38 + 8.37 + 9.14 + 9.86 +10.55 +11.21 +11.76
- 7.54 - 4.32 - 1.32 + 1.32 + 3.58 + 5.29 + 6.64 + 7.65 + 8.43 + 9.16 + 9.86 +10.54 +11.10
- 8.51 - 5.20 - 2.13 + 0.56 + 2.82 + 4.57 + 5.90 + 6.92 + 7.71 + 8.46 + 9.17 + 9.86 +10.42
- 9.50 - 6.08 - 2.95 - 0.21 + 2.06 + 3.84 + 5.15 + 6.17 + 6.98 + 7.75 + 8.48 + 9.17 + 9.74
-10.48 - 6.97 - 3.77 - 0.99 + 1.28 + 3.11 + 4.40 + 5.42 + 6.24 + 7.03 + 7.78 + 8.47 + 9.05
-11.46 - 7.87 - 4.61 - 1.77 + 0.50 + 2.34 + 3.64 + 4.66 + 5.50 + 6.30 + 7.07 + 7.76 + 8.35
-12.44 - 8.78 - 5.44 - 2.56 - 0.28 + 1.57 + 2.87 + 3.89 + 4.75 + 5.57 + 6.35 + 7.04 + 7.64
-13.44 - 9.69 - 6.29 - 3.35 - 1.08 + 0.79 + 2.10 + 3.11 + 3.99 + 4.83 + 5.62 + 6.31 + 6.92
-14.43 -10.61 - 7.14 - 4.15 - 1.88 0 + 1.31 + 2.33 + 3.22 + 4.08 + 4.89 + 5.58 + 6.19
Oil Supply Temp
Gas Generator Speed (rpm)
°F (°C)
9,100
9,200
9,300
9,400
9,500
9,600
9,700
9800
9,900
10,000
100 (37.8) 110 (43.3) 120 (48.9) 130 (54.4) 140 (60.0) 150 (65.6) 160 (71.1) 170 (76.7) 180 (82.2) 190 (87.8) 200 (93.3) 210 (98.9) 220 (104.4)
-15.44 -11.53 - 8.00 - 4.95 - 2.67 - 0.79 + 0.52 + 1.54 + 2.45 + 3.32 + 4.15 + 4.84 + 5.45
-16.46 -12.45 - 8.87 - 5.76 - 3.48 - 1.59 - 0.27 + 0.74 + 1.67 + 2.56 + 3.40 + 4.09 + 4.71
-17.46 -13.37 - 9.74 - 6.57 - 4.29 - 2.41 - 1.08 - 0.07 + 0.88 + 1.79 + 2.64 + 3.34 + 3.96
-18.47 -14.31 -10.61 - 7.42 - 5.10 - 3.25 - 1.90 - 0.88 + 0.09 + 1.01 + 1.87 + 2.57 + 3.20
-19.50 -15.24 -11.50 - 8.29 - 5.92 - 4.09 - 2.75 - 1.70 - 0.71 + 0.23 + 1.09 + 1.80 + 2.44
-20.52 -16.19 -12.39 - 9.17 - 6.75 - 4.95 - 3.59 - 2.53 - 1.52 - 0.56 + 0.29 + 1.02 + 1.66
-21.56 -17.14 -13.28 -10.05 - 7.58 - 5.80 - 4.45 - 3.37 - 2.34 - 1.36 - 0.51 + 0.23 + 0.88
-22.60 -18.10 -14.18 -10.94 - 8.43 - 6.67 - 5.32 - 4.21 - 3.16 - 2.16 - 1.31 - 0.58 + 0.09
-23.65 -19.07 -15.08 -11.84 - 9.31 - 7.54 - 6.19 - 5.06 - 3.99 - 2.98 - 2.13 - 1.39 - 0.70
-24.70 -20.04 -15.99 -12.75 -10.19 - 8.42 - 7.07 - 5.92 - 4.83 - 3.80 - 2.95 - 2.20 - 1.51
NOTE:
Oil MIL-L-7808
Example:
Observed NGG 8,600 rpm Observed Oil Pressure 40 psig (275.8 kPa) Oil Temperature 140°F (60.0°C) Pressure Additive +1.28 psig (8.8 kPa) Corrected Pressure 40 + 1.28 = 41.28 psig (284.6 kPa)
4-7
GEK 105162
Figure 4-2. Lubricating Oil Pressure Correction for LM2500+ SAC Gas Turbines using Lubricating Oil, MIL-L-7808 4-8
GEK 105162
4-3.4.1.2
Lubricating Oil Supply Pressure at Pressure Tap vs. Gas Generator/Gas Turbine Speed
Figures 4-3 and 4-4 provide nominal oil supply pressures at pressure tap vs. GG/GT speed and lubricating oil supply temperature for LM2500+ SAC. 4-3.4.2
Air
Maximum airflow through the GT is approximately 185 lb/sec (83.9 kg/sec) 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)
•
When operating in a marine environment, sodium (from air or water) entering the GT should not exceed 0.00045 parts/million (ppm) average, or 0.003 ppm maximum
•
4-3.4.3
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
4-3.4.4
Adjustment of Gas Turbine High Pressure Recoup Cavity Pressure Within Preferred Operating Range NOTE
High pressure recoup should be checked at initial startup and periodically thereafter. Refer to GEK 105163, Chapter 4, and GEK 105164, WP 415 00. Maintenance of GT high pressure recoup cavity pressure (HPRCP) in the preferred operating range is required to ensure No. 4B bearing life. During initial buildup of engine, HPRCP was adjusted to the preferred operating range with the proper size metering spacers. Periodic plotting of the HPRCP is required in service, because seal leakage can change with operation of the engine and may cause HPRCP to fall outside the preferred operating range. Refer to GEK 105164, WP 415 00, for procedure. 4-3.4.5
Adjustment of Power Turbine Thrust Balance Cavity Pressure Within Preferred Operating Range NOTE
PT thrust balance cavity pressure should be checked at initial startup and monitored thereafter. Refer to GEK 105163, Chapter 4, and GEK 105164, WP 428 00.
Liquid Fuel
The requirements for liquid fuel are provided in GEK 105163, Appendix A3. Fuel shall be filtered to 20 microns absolute.
Maintenance of PT thrust balance cavity pressure in the preferred operating range is required to ensure No. 7B bearing life. During initial buildup of GT, PT thrust balance cavity pressure was adjusted into the preferred operating range with the proper size orifice plate.
Change 2
4-9
GEK 105162
Figure 4-3. LM2500+ SAC Gas Turbine Oil Supply Pressure at Pressure Tap vs. GG Speed using Lubricating Oil, MIL-L-7808 4-10
GEK 105162
Figure 4-4. LM2500+ SAC Gas Turbine Oil Supply Pressure at Pressure Tap vs. GG Speed using Lubricating Oil, MIL-L-23699 4-11
GEK 105162
Monitoring of PT thrust balance cavity pressure is required in service because seal leakage can change with the operation of the GT. This may cause PT thrust balance cavity pressure to fall outside of the preferred operating range. Refer to GEK 105164, WP 428 00, for procedure. 4-3.5 Initial Prestart Inspections The GT and package should undergo a thorough prestart inspection during installation or after maintenance to ensure a trouble-free transition from installation to full operation. This inspection will help detect potential installation problems. The following inspections should be performed during installation into the enclosure: a. Inspect enclosure per packager’s instructions. b. Perform external inspection. Ensure all connections are tight and that no binding or chafing is evident on flexible electrical cables, hoses, or tubes. c. Ensure bonding straps are in place and secure. d. Inspect GT inlet area. Thoroughly inspect inlet plenum for dirt and foreign objects. Clean, vacuum, and/or wash area, as necessary. e. Inspect exhaust system for foreign objects. f. Ensure lubrication system is properly serviced.
4-12
Change 1
g. Inspect for leaks in fuel and lubrication oil lines. h. Ensure compressor rear frame (CRF) leakage ports, struts No. 7 and No. 10, are open (not capped). i. Ensure T5.4 (T48) thermocouple system functions properly. j.
Ensure fire/alarm system is functional.
4-3.6 Initial Operational Checkout CAUTION If a questionable condition exists, do not operate GT 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 on GT components, with immediate or subsequent destructive failure of the GT. The initial startup procedures described in this paragraph should be followed after any GT installation, GG replacement, or major system or GG maintenance. The GT should be operated at various speed/load conditions to establish baseline performance for the specific installation. Refer to paragraph 4-4.4.1c. a. Perform initial prestart inspection per paragraph 4-3.5. b. Perform normal prestart checks per paragraph 4-4.2.
GEK 105162
c. Motor GT for 2 minutes per packager’s instructions and per paragraph 4-4.3. During motoring, check for the following: •
f. Perform ignition system functional check as follows: WARNING
Oil pressure indication
•
Lube oil leaks
•
Unusual noise during coastdown
d.
Perform false start as follows:
(1) With ignition leads disconnected and fuel shutdown 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.
•
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 shutdown valves are closed throughout this procedure.
(1) Motor GG for 1.0 minute to clear combustor of residual fuel. Allow GG to coast down. NOTE
e.
Perform prestart as follows:
(1) With ignition system disabled, fuel shutdown valves open, and governing system operating, make automatic start of GG per packager’s manual. (2) GG should accelerate to applicable light-off speed. Fuel shutdown valves 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. Motor to purge any remaining fuel from GG or drain liquid fuel from manifolds. Continue to motor for minimum 60 seconds to purge fuel from GG. Consult packager’s manual for necessary prestart purge time.
Model 7LM2500-PZ-MLG01 has two ignition systems. (2) Disconnect ignition exciter input lead at exciter. Temporarily secure input lead away from 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) Repeat steps (2), (3), and (4), disconnecting input lead to second exciter for Model 7LM2500-PZ-MLG01. (6) If audible report is not heard on first or second igniters, check out system to isolate problem, and take appropriate corrective action.
Change 2
4-13
GEK 105162
i.
WARNING When working inside or near the GT enclosure during operation, observe the safety precautions described in paragraph 4-2. g. Perform verification test per paragraph 4-3.7. h. Make normal start (paragraph 4-4.4, Starting and Operation) and set power at IDLE. When GT is stabilized at IDLE, do the following: •
Check GT and supply systems for leaks
•
Check for loose parts, tubing, cabling, etc.
•
Check all parameters and verify that values are within normal range per table 4-3
•
Observe and record all results
•
Correct discrepancies prior to load application
Operate to maximum power as follows:
(1) Slowly increase control setting (per packager’s manual) to increase 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 per GEK 105164, WP 416 00. If vibrations are not within limits, consult local General Electric Company representative. (2) Operate GG to rated power. Output will normally be limited by one of the following: compressor discharge temperature (T3), compressor discharge pressure (PS3), power turbine inlet temperature (T5.4 [T48]), or on extremely cold days, corrected core speed. Hold at this power setting until engine stabilizes. NOTE Normal operating parameter ranges and limits are shown in table 4-3, table 4-4, and figure 4-5. (3) Compare recorded readings to typical values in table 4-3 and troubleshoot as required. (4) stabilized.
Log all instrument readings once
Table 4-3. Typical Operating Levels Max Operating Limit (Note 1)
Parameter
Idle
Max Power
T2, °F (°C) (Inlet temperature)
-65 to 150 (-53.9 to 65.6)
-65 to 150 (-53.9 to 65.6)
N/A
P2, psia (kPa absolute) (Inlet pressure)
14.5-14.8 (99.97-102.04)
14.5-14.8 (99.97-102.04)
N/A
NGG, rpm (Gas generator speed)
6,800-7,400 (Note 2)
10,100
10,100
4-14
Change 1
GEK 105162
Table 4-3. Typical Operating Levels - (cont.) Max Operating Limit (Note 1)
Parameter
Idle
Max Power
PS3, psia (kPa absolute) CDP
40-55 (275.8-379.2)
280-320 (1,930.5-2,206.3)
Note 6
T3, °F (°C) (Compressor discharge temperature)
285 to 365 (140.6 to 185.0)
835 to 890 (446.1 to 476.7)
935 (501.6)
WF36, lb/hr (kg/hr) @ 18,400 BTU/lb (10,555 kcal/kg)
1,200-1,500 (544.3-680.4)
12,000-13,000 (5,443-5,896)
N/A
PT5.4 (PT48), psia (kPa absolute) (Power turbine inlet pressure)
17-19 (117.2-131.0)
60-70 (413.7-482.6)
N/A
T5.4 (T48), °F (°C) (see figure 4-4) (PT inlet temperature)
1,150 to 1,350 (621.1 to 732.2)
1,455 to 1,592 (790.6 to 866.7)
1,592 (Note 3) (866.7)
PT speed for 60 Hz (rpm)
0 - 3600
4,140
PT speed for 50 Hz (rpm)
0 - 3000
4,140
VSV position, degrees
30 to 34
4 to 8
N/A
Oil supply pressure, psig (kPa gage)
8-15 (55.2-103.4)
20-60 (137.9-413.7)
N/A
Oil supply temperature, °F (°C)
140 to 160 (60.0 to 71.1)
140 to 160 (60.0 to 71.1)
200 (Note 4) (93.3)
Oil scavenge pressure, psig (kPa gage)
See appropriate packager manual
5-100 (34.4-689.4)
100 (Note 4) (689.4)
Oil scavenge temperature increase (A/TGB-sump), °F (°C) (Note 5)
10 to 30 (5.6 to 16.7)
30 to 65 (16.7 to 36.1)
340 (171.1)
Lube scavenge temperature increase (B-sump), °F (°C) (Note 5)
10 to 15 (5.6 to 8.3)
70 to 120 (38.9 to 66.7)
340 (171.1)
Lube scavenge temperature increase (C-sump), °F (°C) (Note 5)
10 to 40 (5.6 to 22.2)
60 to 110 (33.3 to 61.1)
340 (171.1)
Lube scavenge temperature increase (D-sump), °F (°C) (Note 5)
10 to 40 (5.6 to 22.2)
20 to 80 (11.1 to 44.4)
340 (171.1)
Change 1
4-15
GEK 105162
Table 4-3. Typical Operating Levels - (cont.)
Parameter
Idle
Max Power
Max Operating Limit (Note 1)
Lube scavenge temperature increase (TGB), °F (°C) (Note 5)
10 to 30 (5.6 to 16.7)
20 to 50 (11.1 to 27.8)
340 (171.1)
Liquid fuel manifold pressure, psig (kPa gage)
900 psig (6,205.3)
Liquid fuel manifold temperature, °F (°C)
Note 7
Note 7
160 (71.1)
Recoup pressure, psig (kPa gage)
See GEK 105163, Chapter 4
See GEK 105163, Chapter 4
See GEK 105163, Chapter 4
NOTE 1: Unless otherwise noted, limits are shutdown limits. Reference GEK 105163, Chapter 3, 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). NOTE 3: Limited to 1,535°F (834.9°C) on a 3,600 rpm power turbine; shutdown limit 1,592°F (866.7°C). NOTE 4: Alarm only. NOTE 5: Increase in scavenge temperature over oil supply temperature. Alarm limit 300°F (148.9°C). NOTE 6: Governed by PS3/P2 schedule, application specific. NOTE 7: Range for all conditions is > 20ºF above wax point of fuel to < 160ºF (71.1ºC).
Table 4-4. Limits and Operating Requirements Event/Item
Max Limits/Requirements
Max time allowed for ignition
t ≥ 20 seconds after fuel/ignition application
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 - Alarm
> 7 mils - Shutdown
PT rotor vibrations
> 7 mils - Alarm
> 10 mils - Shutdown
4-16
Change 1
GEK 105162
Figure 4-5. Transient Temperature Limits (Typical) 4-17
GEK 105162
4-3.7 Verification Test If a verification test is not specified by packager, the verification test described below should be performed after initial operational checkout (paragraph 4-3.6) has been completed. Record abnormal condition and perform needed corrective action. a. Verify all service systems (electrical, air, fuel, lube oil, fire control, indicators, and controls) are checked out and ready for operation.
f. Stabilize at full power for 3 minutes. Observe and record data specified in table 4-3. g.
Reduce power to IDLE.
h. Perform normal shutdown per paragraph 4-4.5.1. i. Inspect for leakage and loose parts. Take corrective action as required. j. Check lube and scavenge pump screens for evidence of contamination.
b.
Start gas turbine per paragraph 4-4.4.
4-4
c.
Hold at IDLE for 5 minutes minimum.
Operational procedures are presented in this paragraph. Prior to operation of the GT, ship operators should be thoroughly trained in both normal and abnormal (emergency) operations and the control system action/reaction to these conditions. This section offers guidelines for tracking GT operation times and maintenance actions. A thorough history of GT performance will aid in further operations and maintenance decisions.
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, shut down manually and check speed indication and automatic shutdown systems. e. Restart GT and slowly advance to full power. If acceleration follows cold start, rate should not exceed zero to maximum load in less than 5 minutes. A constant rate load increase should be maintained during acceleration.
4-18
GAS TURBINE OPERATION
GEK 105162
4-4.1 Component Life/Repair Intervals
•
Oil supply valves are open
Safe operation of the LM2500+ SAC is dependent on properly scheduled maintenance, repairs, and component replacement. To properly track these conditions, packager-supplied time and event counters provide data for the parameters.
•
Lubricating oil temperature is above 20°F (-6.7°C) for lubricating oil, MIL-L-23699, or above -20°F (-28.9°C) for lubricating oil, MIL-L-7808
•
T5.4 (T48) 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
•
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
4-4.2 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 inlet and enclosure have been inspected and cleaned in accordance with instructions in packager’s manual
•
Fuel shutdown valves are closed
•
Ignition system is off
•
Oil tank level is full
Although not required as part of normal starting procedures, motoring is frequently used following maintenance to check GT prior to making a start. Motoring is performed with fuel shutdown valves closed.
Change 1
4-19
GEK 105162
4-4.3 Motoring Procedures
(2) fuel skids.
Close manual shutoff valve(s) to
CAUTION If a questionable condition exists, do not operate the GT 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 GT components, with immediate or subsequent destructive failure of the GT.
WARNING •
Lubricating oil, MIL-L-7808: Combustible. Do not inhale, ingest, or let this material touch you. If ingested, central nervous system damage/adverse effects. If ingested, can produce paralysis. Irritant. Thermal decomposition may release toxic by-products. Personal protective equipment required. Use in a well-ventilated area. If heated, use an approved respirator.
•
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.
NOTE Be certain that checklists have been established for packager-furnished equipment. Consult the packager’s manual for mandatory prestart procedures. Make certain that the packager-furnished oil supply subsystem is activated and operational prior to motoring or start sequence. After all preliminary checks have been completed and lines flushed, GG can be motored as follows: a. Make ignition and fuel supply systems inoperative as follows: NOTE Model 7LM2500-PZ-MLG01 has two ignition systems. (1) Disconnect power supply to ignition system(s).
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Change 2
b. Motor GG until 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. c. Repeat motoring and bleeding procedure until indication of oil pressure appears.
GEK 105162
4-4.4 Starting and Operation 4-4.4.1
b. Engage starter or initiate start sequence. The following should occur:
Normal Starting Sequence •
Engine will begin to rotate and accelerate to greater than 1,700 rpm and stabilize
•
Ignition will be energized 2 minutes after reaching 1,700 rpm
•
Fuel shutoff valves will open
•
Lightoff should occur in approximately 5 seconds
•
PT rotor will start to rotate before GG reaches IDLE speed
•
Engine will accelerate to IDLE (starter-assisted to 4,500 rpm, where starter-cutout occurs)
•
Finish 5 minute warmup prior to loading
•
Check parameters per table 4-2
•
Accelerate to desired load. Maintain constant rate of load increase during acceleration
WARNING For maximum safety, operating personnel should remain clear of the plane of the GG starter when starting unit and should remain clear of 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 GG sound levels may cause hearing loss. CAUTION If a questionable condition exists, do not operate GT 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 on GT components, with immediate or subsequent destructive failure of the engine. a. Ensure all prestart checks have been completed. NOTE
c. Check and record levels of operating parameters designated in tables 4-1 and 4-2. If all parameters shown in tables are normal, GT operation may continue. If GT parameters are outside normal operating limits shown in the tables, troubleshoot and correct problem per GEK 105163, Chapter 3, before continuing.
A start may be aborted at any time by closing fuel shutdown valves, allowing gas generator to motor for 60 seconds, then closing starter shutoff valve.
4-21
GEK 105162
4-4.4.2
Hot Starts
a. Starts indicating T5.4 (T48) 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 (537.8° to 648.9°C).
4-4.5.1
CAUTION •
Thermal seizure of the PT rotor can occur when a hot GT is shut down and may cause engine damage. Thermal seizure is the condition where the PT rotor is prevented from rotating by hard contact between PT rotor blades and shrouds, interstage seals and other internal interference. It is most likely to occur within 30 to 40 minutes following GT operation. This condition is the result of unequal cooling rates of various PT components. The possibility of thermal seizures can be reduced by operating GT at IDLE power for at least 5 minutes before shutdown to achieve proper cooling of the PT.
•
Ensure fuel manifold is drained when GT is shut down or GT damage could occur. The maximum temperature of the fuel will be 200° F (93.3° C). Refer to packager’s manual for procedure.
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 hot start occurs, startup procedure should not be repeated without investigating cause of hot start. For troubleshooting procedures, refer to GEK 105163, Chapter 3. 4-4.5 Shutdown NOTE The information presented herein describes a typical sequence of events. However, for specific control sequencing modes and ship operation information, see the packager’s manual. The following types of GT shutdowns may occur: •
•
4-22
Normal shutdown: GT is taken offline for a specific reason, annunciated fault, or other indication of problem which operator interprets as reason for taking GT off-line, or for reasons not necessarily related to GT. Emergency shutdown: GT is taken off-line by operator or control system to prevent damage or injury to equipment or personnel due to GT or system fault.
Normal Shutdown
Shutdown procedures are dependant on application. See packager’s manual. Under normal operating conditions, GT is shut down in sequence described below: •
Power is reduced to minimum load (IDLE) or control sequencer is activated to accomplish shutdown
•
HP rotor speed decreases to approximately 7,600 rpm (sync idle/min-load) over 2-3 minute period
•
T5.4 (T48) decreases
GEK 105162
b. Underspeed and oil pressure alarms are bypassed.
NOTE After shutdown, natural circulation of air through the GT must not be interrupted. •
c. Vent/drain valves are opened per control sequencing.
GT should decelerate to IDLE speed, approximately 6,800 rpm, where GT should be allowed to cool for 5 minutes. After 5 minutes, fuel shutdown valves should be closed and drain valves opened
4-4.5.2
CAUTION Ensure freedom of rotation of GT after emergency shutdown from high power settings. Seizure of GT 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 GT 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:
Table 4-5 outlines the protection functions that require root cause resolution prior to GG motoring.
a. Fuel shutdown and metering valves are closed. Table 4-5. Protective Function Causes Requiring Resolution Prior to Restart or Motoring Protective Function Excessive vibration alarm/shutdown Fire system shutdown and/or Halon release GT lubrication oil supply pressure low alarm/shutdown Lubrication scavenge alarm/shutdown Overspeed alarm/shutdown Oil filter pressure drop alarm/shutdown Enclosure high combustible gas level shutdown Lubrication scavenge pressure alarm Chip detector alarm Starter system failure Fail to crank indication Negative rate of change of PS3 (-dPS3/dT) shutdown (stall indication)
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GEK 105162
4-4.5.3
Post-Shutdown Fire
During normal shutdown, GG T5.4 (T48) should decrease following closure of fuel shutdown valves. If T5.4 (T48) temperature increases after fuel shutdown valves are released, combustion is still continuing. (Slight temperature increase after rotation stops is normal.) Ensure fuel is shut off, and motor GG (paragraph 4-4.3) to extinguish combustion. When temperature decreases to normal, discontinue motoring. If condition persists refer to GEK 105163, Chapter 3, Troubleshooting. 4-4.6 Starter Duty Cycle NOTE Starter duty cycle applies only to GE supplied starters. There is no duty cycle limit on hydraulic starter as long as oil temperature is maintained below 200°F (93.3°C). 4-4.7 Restart CAUTION If a questionable condition exists, do not attempt to motor or operate GT until a thorough investigation of the condition has been completed. Do not restart GT until causes for emergency shutdowns or aborted operations are thoroughly investigated and corrected. Failure to do so can result in undue stress on engine components and may result in damage and ultimate failure.
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This paragraph addresses requirements for restarts after operation at power. Restarts may be initiated at any time if prior shutdown sequence was normal. Restarts following emergency shutdown or trip from operation at power may be restricted, depending on cause. 4-4.7.1
Hot Restarts
A restart following emergency shutdown or trip from a power level where T5.4 (T48) is higher than 1,150°F (621.1°C) is considered a hot restart sequence and should not be attempted until fault or circumstance triggering 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 4-3. If fault which caused an emergency shutdown is fully understood, resolved, cleared, and has been verified that no damage to the GT has occurred, restart or motoring sequence can be initiated.
GEK 105162
It is critical that the hot restart procedure follows a specific sequence to avoid major GT 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. Restart procedure following a trip from power or an emergency shutdown (T5.4 [T48] greater than 1,150°F (621.1°C)) is as follows: a. If hot restart is performed within 2 hours following emergency shutdown, motor GT at 2000-2500 rpm NGG for 5 minutes. Prior to initiating motoring, ensure rotor is free to rotate and not seized. At the end of 5 minute motoring/purge cycle, perform normal restart and accelerate to IDLE. Acceleration to desired power setting can then be accomplished. b. After 2 hours following coastdown of HPCR, restart can be made using normal starting procedure.
b. GG may windmill for periods up to 5 minutes at speeds between 100-1000 rpm, provided each period is preceded by normal GT operation. Extended windmilling of GG outside these limits may be carried out, but require additional equipment and protection. Contact GE Marine Customer Service, 1 Neumann Way, Mail Drop S-156, Cincinnati, Ohio 45215-6301, USA, for assistance. 4-4.9 Records and Running Logs A log should be kept of all GT operation and/or running time. It is recommended, as a suggested minimum, ship operators record the following: •
Time of all starts and shutdowns
•
Total time for GT and ship
•
Reading of all GT instrument recordings, taken twice daily at set-load point
•
All changes of GT speed and load
•
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 GT
4-4.8 Windmilling Windmilling is generally caused by air forced through the inlet, causing rotors to turn. Windmilling also occurs during shutdown as kinetic energy of the rotor is dissipated by pumping and rolling-element friction. Duration of GG windmilling is limited by the lubrication of the rotor bearings. The following defines these limits: a. GG may windmill for 2 weeks in duration at speeds below 100 rpm, provided each period is preceded by normal GT operation.
Change 2
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GEK 105162
4-5
ABNORMAL OPERATION
This paragraph 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.
4-7.1 Alarms Alarms 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 GEK 105163, Chapter 3, for the problem events and system conditions that trigger alarms and protective functions. 4-7.2 Power Cutback
4-6
GENERAL DEFINITIONS
Abnormal operation is defined as any type of 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 to: •
Prevent damage to GT or installation
•
Prevent injury to personnel
4-7
CONTROL ACTIONS
There are three levels of protection initiated by the packager-supplied control system when abnormal conditions are sensed: •
Alarms (alarm-only conditions)
•
Power cutbacks
•
Shutdowns
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There is a power cutback function in the control that 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 GT schedules and GT cooling to be maintained. Rather than decelerate all the way to IDLE, the GT 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. 4-7.3 Shutdowns There are five shutdown functions in the controls as follows: •
Shutdown (GT motoring allowed)
•
Emergency shutdown (GT motoring not allowed)
•
Step deceleration to IDLE/shutdown
•
Slow deceleration to IDLE/shutdown
•
Abort start/shutdown
GEK 105162
These functions initiate an alarm and a shutdown, but vary in their shutdown sequence.
4-7.3.3
4-7.3.1
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 GT than does an immediate shutdown at power. The 10-second pause at IDLE, allows various scheduled GT systems, such as variable stator vanes, to reach stabilized condition before shutdown occurs.
Normal Shutdown
A control-initiated shutdown is a controlled deceleration to IDLE, a 5-minute stabilization period, a closing of the fuel shutdown valves, and opening of drain or vent valves. 4-7.3.2
Emergency Shutdown
A control-initiated emergency shutdown occurs when the GT must be shut down immediately to prevent severe damage to the GT or installation.
Step Deceleration to IDLE/ Shutdown
When step deceleration occurs, control initiates the following sequence of events:
When an emergency shutdown occurs, the control initiates the following events:
a. Power is immediately reduced to IDLE, causing GT to decelerate as rapidly as possible.
a. Fuel shutdown valves and metering valve are closed.
b. When GT reaches IDLE speed, the control holds at IDLE for 10 seconds and then initiates a shutdown. Hold at IDLE allows the GT to be shut down from an on-schedule, stabilized condition.
b. Underspeed and oil pressure alarms are bypassed. c. Drain and vent valves are opened per control sequencing. d. Alarms, interlocks, sequence timers, and operating timers are reset. NOTE The emergency shutdown will not allow reset until NGG is less than 400 rpm. Table 4-5 outlines the protection functions that require root cause resolution prior to GG motoring.
c. When control initiates the shutdown after the 10-second IDLE hold, the following events occur: •
Fuel shutdown 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
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GEK 105162
4-7.3.4
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. When GT reaches IDLE speed, the control holds at idle for 10 seconds and then initiates a shutdown. Hold at IDLE allows the GT to be shut down from an on-schedule, stabilized condition. b. When control initiates the shutdown after the 10 second IDLE hold, the following events occur: •
Fuel shutdown valves are closed
•
Underspeed and oil pressure alarms are bypassed
•
•
4-7.3.5
Drain and vent valves are opened per control sequencing Alarms, interlocks, sequence timers, and operating timers are reset
4-8
•
Drain and vent valves are opened per control sequencing
•
Alarms, interlocks, sequence timers, and operating times are reset
•
A purge cycle is initiated by the control, if applicable OPERATOR ACTION
To avoid GT damage or more severe protective action, operators must correct the causes of all alarms and determine corrective actions necessary to clear abnormal conditions. Consult troubleshooting procedures in GEK 105163, Chapter 3, before resuming normal GT operation. After a power cutback or shutdown, positive action to correct the cause is necessary. For an alarm or protective action, the following general procedures should be followed: a. Acknowledge alarm as specified in packager’s manual. b. During an alarm-only condition, correct problem, if in question, contact packager/GE Marine Service, before resuming normal operation.
Aborted Start/Shutdown NOTE
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, control initiates the following events: •
Fuel shutdown valves are closed
•
Ignition system and starter are deenergized
•
Underspeed and oil pressure alarms are bypassed
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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 power cutback, correct problem before resuming operation at power. If recovery is not possible, shut down and correct problem. d. After normal shutdown, correct problem before attempting restart.
GEK 105162
CAUTION It is critical that the restart procedure, following an emergency shutdown, follow the specific sequence outlined in paragraph 4-4.7.1, to avoid major GT damage.
4-8.1.1
Overtemperature During Starting
f. Enter appropriate comments in GT log concerning any problems and corrective actions.
During starting and acceleration to IDLE, cooling airflow to components of the GG hot section are not sufficient to protect the metal at T5.4 (T48) alarm and trip levels specified in the limits table, per paragraph 4-4, GT Operation, and GEK 105163, Chapter 3, Troubleshooting. A lower T5.4 (T48) limit is therefore established, with higher levels acceptable, provided levels exist for limited times. This shall be monitored by the operator. The overtemperature inspection, called for by entry into area B in Figure 4-5, requires hot section disassembly and inspection in a qualified facility.
4-8.1 Special Gas Turbine Constraints
4-8.1.2
Under normal operating conditions, the GT is constrained by the operating limits published in table 4-2. Continuous operation between the alarm and shutdown or trip level should not be practiced.
The lubricating oil supply pressure limits given in table 4-2 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 tables, 4-1 or 4-2, to determine if the lubricating system is performing within the limits stated in each table.
e. After emergency shutdown, correct problem before attempting restart. For restart procedure following an emergency shutdown, refer to paragraph 4-4.7.1.
In the event that any of the following situations or events occur, the associated special action or limitation shall be followed to ensure the GT continues normal operation. These events may not be detected or may not be prevented by the customary protective devices of control systems: •
Overtemperature during starting
•
Lubricating oil pressure
•
High speed stalls
•
Restart, following high power trip
•
No PT rotation
4-8.1.3
Lubricating Oil Pressure
High Speed Stall
The control system incorporates a stall detection feature to preclude continued operation in a stall condition, once a stall is detected. 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.
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GEK 105162
NOTE A compressor stall may be secondary to another condition. Conduct thorough inspection of GT before restart is attempted. 4-8.1.4
Restart Following High Power Trip
If restart of GT is required within 2 hours following trip or rapid shutdown from high power, 5-minute motoring at 2,000-2,500 rpm must precede restart. Motoring is required to cool HPTR, so that blade tips maintain clearance with more rapidly cooling case. Ensure HPTR is free prior to initiating motoring. 4-8.1.5
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 accelerate to 6,000 rpm. Do not exceed 6,000 rpm. Power turbine rotor should break away. If not, shut down and investigate for unlatched or shingled blades, or other cause.
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4-9
TEST NO. 1 AND NO. 2 FUEL SHUTDOWN VALVE OPERATION CAUTION If gas turbine does not shut down when No. 1 fuel shutdown valve is selected, shut down using No. 2 fuel shutdown valve. Use emergency shutdown procedure if shutdown cannot be accomplished with either valve
a. Place FUEL SHUTDOWN VALVE TEST switch to VALVE 1 on ship control panel (SCP) and hold momentarily. If gas turbine does not shut down, log and take corrective action immediately. Troubleshoot fault per packager’s manual. b. Start gas turbine per paragraph 4-4 and stabilize at IDLE power. CAUTION If gas turbine does not shut down when No. 2 fuel shutdown valve is selected, shut down using No. 1 fuel shutdown valve. Use emergency shutdown procedure if shutdown cannot be accomplished with either valve. c. Place FUEL SHUTDOWN VALVE TEST switch to VALVE 2 on SCP and hold momentarily. If gas turbine does not shut down, log and troubleshoot fault per packager’s manual.
GEK 105162
4-10 TEST POWER TURBINE OVERSPEED SWITCH a. To check channel B, enter enclosure and identify packager’s lead to PT speed pickup (channel A). Disconnect the forward connector of packager’s lead from PT speed sensor lead at panel bracket mounted at 8:00 o’clock on the Turbine Rear Frame (TRF) forward flange. b. Perform automatic start of GT. Declutch coupling shaft from reduction gear and release brake. CAUTION Do not exceed 4,000 rpm NPT or damage may result. c. Slowly increase throttle to 3,900 rpm NPT. Gradually increase throttle until overspeed tripout occurs (GT will shut down). Overspeed tripout shall occur at 3,960 ±40 rpm. If automatic tripout did not occur, perform normal shutdown of GT. CAUTION Failure to follow electrical connector installation procedure may result in moisture contamination and short circuits. d. Connect electrical connector that was disconnected in step a., finger-tight. Remove connector and inspect seal ring for proper seating; reinstall connector finger-tight. Using slip-joint pliers, tighten connector 5-20 degrees past finger-tight, and safety-wire.
f. Perform automatic start. Declutch coupling shaft from reduction gear and release brake. CAUTION Do not exceed 4,000 rpm NPT, or damage may result. g. Slowly increase throttle to 3,900 rpm NPT. Gradually increase throttle until overspeed tripout occurs (GT will shut down). Overspeed tripout shall occur at 3,960 ±40 rpm. If automatic tripout did not occur, perform normal shutdown. CAUTION Failure to follow electrical connector installation procedure may result in moisture contamination and short circuits. h. Connect electrical connector that was disconnected in step f, finger-tight. Remove connector and inspect seal ring for proper seating; reinstall connector finger-tight. Using slip-joint pliers, tighten connector 5-20 degrees past finger-tight, and safety-wire. i. If overspeed trip on channel A or B did not occur within specified tolerance, troubleshoot PT overspeed switch per packager’s manual. j. Return GT to required state of operation per packager’s manual.
e. To check channel A, identify packager’s lead to PT speed pickup (channel B). Disconnect forward connector of lead from PT speed sensor lead at panel bracket mounted at 8:00 o’clock on the TRF forward flange.
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GEK 105162
4-11 TEST POWER TURBINE SPEED LIMITING SYSTEM
d. Slowly advance throttle and verify that PT does not exceed 3,852 rpm.
a. If GT is not operating, perform start per paragraph 4-4 and stabilize at IDLE power setting.
e. If PT speed exceeds 3,852 rpm, shut down GT and immediately report discrepancy to maintenance group supervisor. Troubleshoot PT speed limiting system per packager’s manual.
b. Declutch coupling shaft from primary reduction gear and release brake. c.
Set PT speed at 3,600 rpm. CAUTION
Do not exceed 3,852 rpm, or damage may result.
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f. Return GT to required state of operation per packager’s manual.
