GE Aero Energy Products Chapter 2

A GE Power Systems Business Table of Contents

Chapter 2, Maintenance

Table of Contents

Title Page

General Information ................................................................................................................................2-1-1

Scope .......................................................................................................................................................2-1-1
General Maintenance Concept ................................................................................................................2-1-1

Servicing .................................................................................................................................................2-2-1

Preventive Maintenance ..........................................................................................................................2-2-1

Preventive Maintenance Procedures .......................................................................................................2-2-5
Required Lubricants and Consumables.................................................................................................2-2-10

Troubleshooting ......................................................................................................................................2-3-1

Prime Mover ...........................................................................................................................................2-3-1

Generator ................................................................................................................................................2-3-1
Ancillary Equipment ...............................................................................................................................2-3-1

Repairs and Adjustments ........................................................................................................................2-4-1

Prime Mover ...........................................................................................................................................2-4-1

Generator ................................................................................................................................................2-4-1
Engine to Generator Alignment ..............................................................................................................2-4-1
Ancillary Equipment ...............................................................................................................................2-4-7
Special Tools...........................................................................................................................................2-4-8

601178 2-TOC-i
5450TU Orig
Chapter 2 GE Aero Energy Products
Table of Contents A GE Power Systems Business

This Page Intentionally Left Blank

2-TOC-ii 601178
Orig 5450TU
GE Energy Chapter 2
Section 1

Chapter 2, Section 1

General Information

SCOPE

The following maintenance instructions provide a guide to conduct operator-level maintenance of the GE
Energy Model TM2500 MGTG set. Maintenance information for the vendor-supplied equipment is
provided in Chapter 5 of this manual.

GENERAL MAINTENANCE CONCEPT

On-Condition Maintenance

The maintenance concept for the turbine-driven generator is generally referred to as on-condition
maintenance, which eliminates scheduled overhaul based on operating hours. Under the on-condition
concept, ancillary turbine-driven equipment is inspected on a regular schedule and repaired as necessary to
restore the unit to operational serviceability. See Table 2.1, Turbine Engine On-Condition Maintenance
Inspection/Check Schedule; Table 2.2, Generator Inspection Intervals; and Table 2.3, Ancillary Equipment
Maintenance Schedule in Section 2 of this chapter. Two factors determine the extent of repairs under this
concept:

1) Correction of the primary cause of failure and/or discrepancy and any resultant secondary damage.

2) Replacement or repair of parts that do not meet established inspection criteria defined in the
technical manual.

On-Site Maintenance

On-site maintenance falls into the categories of preventive scheduled maintenance and corrective
unscheduled maintenance.

Preventive maintenance is described as scheduled maintenance based on operating hours or those

scheduled to coincide with some event, or a combination of both, or as a result of monitoring
conditions.

Corrective maintenance is described as unscheduled maintenance performed to correct a

malfunction as a result of failure or impending failure detected by inspection and/or condition
monitoring.

During operation, the following items are monitored: gas generator speed, power turbine speed, gas
generator and exhaust gas temperature, engine and driven equipment vibrations, oil pressure, oil temperature,
and normal and peak operating times.

Under the on-condition maintenance philosophy, scheduled maintenance actions requiring shutdown can be
accomplished concurrently at intervals of 4000 hours or 6 months and 8000 hours or 12 months.

20100 2-1-1
2433123 Orig
GE Energy Chapter 2
Section 2

Chapter 2, Section 2

Servicing

PREVENTIVE MAINTENANCE

The schedules in Table 2.1, Turbine Engine On-Condition Maintenance Inspection/Check Schedule;
Table 2.2, Generator Inspection Intervals; and Table 2.3, Ancillary Equipment Maintenance Schedule
describe the recommended inspection intervals for the TM2500 MGTG set. Recommended maintenance
level codes are defined as (1) Level I, Minor Repair; (2) Level II, Heavy Repair; and (3) Level III,
Restoration. Maintenance level codes are assigned based on the degree of complexity.

Table 2.1, Turbine Engine On-Condition Maintenance Inspection/Check Schedule

Inspection Check Inspection Maint.

Item Required Frequency Level Remarks

1 Engine Oil Level Daily I Check oil level and check system for
oil leaks.

2 General Condition Weekly I Inspect external engine components

of Engine for security of installation.

3 Engine Mounts 500 Hours I Check for security, cracks, and

isolation deterioration.

4 Electrical Harness 500 Hours I Check for security; check ignition

Leads & Cables leads and thermocouple harness for
burning or chafing.

5 Control Linkage 500 Hours I Check for freedom of movement, rod

end wear, and security.

6 Magnetic Plugs 500 Hours or after I, II, III Continuity check for particle
internal failure accumulation. Should also be
checked after internal engine failure.

7 Engine Plumbing 500 Hours I Check fuel and oil plumbing line to
and on engine for security, chafing,
and leaks.

8 Lubricating Oil 1 Month or 700 hours, or I, II Have oil sample analyzed.

after oil change

9 Compressor Cleaning As required I Water wash (refer to procedures in

this chapter and section).

10 Fuel Filters 2000 Hours or as I Check for cleanliness and damage.

required by Delta P

20100 2-2-1
2433123 Orig
Chapter 2 GE Energy
Section 2

2-2-2 20100
Orig 2433123
GE Energy Chapter 2
Section 2

Table 2.1, Turbine Engine On-Condition Maintenance Inspection/Check Schedule (Cont)

Inspection Check Inspection Maint.

Item Required Frequency Level Remarks

11 Thermocouple Ring 4000 Hours I Check thermocouple calibration.

12 Mechanical Linkages 4000 Hours I Check for wear.

13 Engine Inlet & 4000 Hours I, II, III Maintenance level depends on
Compressor Assy. inspection findings.

14 Engine Oil Filter 6 Months or I Remove, inspect, replace

4000 hours, or as filter.
required by Delta P

15 Igniters & Liner 6 Months or I Inspect at 4000 hours, then every

Supports 4000 hours 12 months or 8000 hours.

16 Thermocouples & Wiring 6 Months or I, II Inspect first at 500 hours, then 1000
4000 hours hours, then each 4000 hours.

17 Turbine First Stage 6 Months or I, II Inspect first at 500 hours, then 4000
4000 hours hours or 6 months.

18 Combustor 6 Months or I, II Maintenance Level III depends on

4000 hours inspection findings.

19 Fuel Nozzles 6 Months or I Inspect for carbon and wear at 500

4000 hours hours, then at 4000 hours.

20 RPM & Temperature 6 Months or I, II Check for accuracy. Calibrate if

Control 4000 hours necessary.

21 Combustible Gas 6 Months or I Calibrate in accordance with

Detector Calibration 4000 hours instructions in Wilson Fire and Gas
Protection System manual in
Chapter 5.

22 Engine-to-Generator 12 Months or I Check for accuracy. Adjust if

Alignment 8000 hours necessary. Refer to Installation
Manual for procedures.

20100 2-2-3
2433123 Orig
Chapter 2 GE Energy
Section 2

Table 2.2, Generator Inspection Intervals

Inspection Check Inspection Maint.

Item Required Frequency Level Remarks

1 Lube Oil Level Daily I Check reservoir sight gauge for

positive flow. Use oil recom-
mended in Table 2.4.

2 Bearing Drains Daily I Check that flow is being

maintained.

3 Vibration Signatures Weekly I Check Bently Nevada gauges for

vibration measurement.

4 Rotor Winding 1000 Hours, I Requires 500V megohmmeter.

Insulation or as required Refer to FKI manual in Chapter 5
for proper procedure.

5 Lubricating Oil 6 Months or I Have oil samples analyzed.

4000 hours, or when
oil is changed

6 Oil Pump Coupling 4000 Hours I Visually inspect for separation of

rubber-to-metal bond.

7 Bearings 12 Months or I, II Maintenance level depends on

8000 hours findings.

8 Instrumentation 12 Months or I, II Calibration of the Bently Nevada

8000 hours gauges, pressure, and temperature
switches.

9 Bearing Insulation 12 Months or I Check resistance (refer to FKI

8000 hours, or manual in Chapter 5).
as required

2-2-4 20100
Orig 2433123
GE Energy Chapter 2
Section 2

Table 2.3, Ancillary Equipment Maintenance Schedule

Inspection Check Inspection Maint.

Item Required Frequency Level Remarks

1 General Conditions Daily I General appearance and integrity

of unit.

2 CO2 Level Weekly I Check per Chapter 2, Section 2,

CO2 Weight and Pressure Check.

3 Fluid Filters 3 Months or I Check for blockage.

2000 hours, or as
required by Delta P

4 Mount/Piping/Valves 6 Months or I Check for leaks, cracks, and proper

4000 hours alignment.

5 Thermocouples 6 Months or I Check for secure connections.

4000 hours

6 Fluid Couplings 6 Months or I Check for leaks and system

4000 hours integrity.

7 Control Panel 6 Months or I Check for cleanliness and secure

4000 hours electrical connections.

8 Air Inlet Filters 6 Months or I Check for cleanliness.

4000 hours, or as
required by Delta P

9 Generator Lube Oil 6 Months or I Replenish grease cups or fittings as

System Auxiliary Lube 4000 hours required per maintenance
Oil Pump instructions.

10 Ventilation Fan 6 Months or I Replenish bearing lubricant per

Bearings 4000 hours maintenance instructions in Chapter
5.

11 Batteries & Battery 6 Months or I Replenish electrolyte, check specific

Chargers (if provided) 4000 hours gravity, clean battery case. Adjust
float-and-equalizing potentiometers,
as required.

12 Optical Flame 6 Months or I Refer to periodic checkout

Detectors 4000 hours procedure in the Wilson manual in
Chapter 5.

13 Control Panel 1 Year or I, II Check for proper calibration.

Instruments 8000 hours

20100 2-2-5
2433123 Orig
Chapter 2 GE Energy
Section 2

Table 2.3, Ancillary Equipment Maintenance Schedule (Cont)

Inspection Check Inspection Maint.

Item Required Frequency Level Remarks

14 Electrical Sensors and 1 Year or I, II Check for proper calibration.

Transducers 8000 hours

15 Gas Sensors To be determined by I, II Refer to Wilson manual in

(Fire and Gas owner Chapter 5 for calibration procedures
Protection System) and criteria.

PREVENTIVE MAINTENANCE PROCEDURES

This section describes the procedure to perform the Level I on-site external preventive maintenance.
Preventive maintenance procedures for vendor-supplied equipment are provided in Chapter 5.

Turbine Compressor Cleaning

The water wash provisions are designed to meet the minimum water wash requirements given in the GE
manual, GEK-97310, and to minimize exposure of service personnel to concentrated cleaning solvents.

For specific guidelines on cleaning scheduling and recommended solvents, see GE manual, GEK-97310, in
Chapter 5 of this manual.

Water Wash, Off-Line

Off-line water wash requires two maintenance persons to be equipped with a two-way communications link
that permits them to communicate easily while the turbine is being motored. Compressor cleaning shall be
carried out in the following steps:

Disconnect the discharge pressure sensing line from the compressor

casing before performing off-line water wash. Failure to disconnect
the line may permit soap and water to accumulate in the line, which
can result in subsequent hot starts with possible damage to the
turbine hot-section components, or cause false signals from the
discharge pressure transducer.

1. Disconnect the discharge pressure-sensing line from the compressor casing. Plug the
disconnected end to prevent water from entering the line.

2-2-6 20100
Orig 2433123
GE Energy Chapter 2
Section 2

Chemicals used in compressor cleaning solution are volatile, toxic,

and highly flammable. Follow the warnings given in GE manual,
GEK- 97310, regarding the handling of cleaning solvents. Failure to
follow guidelines could result in fire or explosion with subsequent
injury to personnel or damage to equipment.

2. If ambient temperatures justify the use of antifreeze, prepare approximately 80 gallons of

water/antifreeze solution. (See GE manual, GEK-97310, for the mixing ratio.)

Dispose of residual wastewater from water wash, in accordance with

EPA and local environmental regulations.

3. Fill water wash tank with 38 gallons of potable water or water/antifreeze solution, as determined
by ambient temperature conditions.

4. Add 2 gallon of cleaning solution to water wash tank.

5. Close tank fill and vent valves.

6. Verify that the turbine control panel (TCP) is energized and functioning normally.

7. Turn Turbine Control switch to Water Wash. Push and hold turbine Water Wash switch, located
on turbine inlet porch. The starter will engage and begin to crank the turbine.

8. Once turbine cranking begins, the air valve will pressurize the tank and the inlet valve to the
turbine wash manifold will open automatically.

9. Hold Water Wash switch in depressed position until all cleaning solution is used up.

10. Allow turbine to coast to a stop. Wait 10 minutes after turbine has stopped before rinsing.

11. Rinse. Fill tank with 40 gallons of potable water or antifreeze/water solution and repeat steps
59, above, at least three times.

12. Blow residual water from turbine inlet nozzle manifold with compressed air.

13. Shut off compressed air and examine turbine inlet. If not cleaned satisfactorily, repeat cleaning
cycle.

14. Operate Turbine Control switch to Hi Crank to initiate a high-speed purge cycle. This purge
cycle should blow most residual water out of the turbine.

15. Remove the plug installed in the end of discharge pressure sensing line in step 1 of this procedure.
Reconnect the compressor discharge pressure (CDP) sensing line to compressor casing port.

20100 2-2-7
2433123 Orig
Chapter 2 GE Energy
Section 2

If turbine is too wet to start, check the CDP transducer and sensing
line for water. Remove all water prior to attempting a fired start.

Note If turbine fails to start on first attempt, place Turbine Control switch in Hi Crank to initiate
an additional high-speed purge cycle to dry turbine sufficiently to permit ignition.

16. Start turbine and operate it at idle (gas generator speed of 50005500 rpm) for 5 minutes to dry it.

Fluid Filter Element Inspection and Replacement

Synthetic lube oil contains tricresyl phosphate, which is highly toxic

and operates at high temperature and pressure.

Fuel system maintenance should be performed only when the

turbine is shut down. Exercise extreme care when servicing fuel or
lube oil system. Fire, explosion, or serious injuries could occur.

1. Disconnect power for the turbine-generator lube oil cooler at the motor control center (MCC).

2. Isolate filter assembly by closing all upstream and downstream valves in designated system lines.
This will prevent contamination of remainder of system and minimize the need to bleed air from
the system lines.

Wear goggles or similar eye protection when loosening lube oil

system fittings, as residual pressure may be present. Do not smoke
or carry an open flame or source of sparks when servicing fuel
system.

3. Loosen vent plug on top of filter head assembly. This will relieve any residual pressure in filter
assembly.

4. Remove the drain plug from bottom of filter bowl and allow fluid to drain into container provided.
Remove vent plug, if necessary, to permit complete drainage of filter.

5. Loosen and remove the knurled ring that clamps the filter bowl to the filter head assembly. Then
remove the filter bowl, clamping ring, and filter element.

Note Filter assemblies come in two types. One type uses a through-bolt and/or nut arrangement to
attach the filter bowl to the filter head. Other filter assemblies include a clamping arrangement or a
threaded filter head.

2-2-8 20100
Orig 2433123
GE Energy Chapter 2
Section 2

6. Examine filter element for damage or evidence of collapse, and observe the amount of dirt and
debris entrapped in element. Check element gaskets for damage and proper seating. Replace
excessively dirty or damaged filter elements.

7. Examine filter element bowl and head assemblies for damage or wear. Check all O-rings and
gaskets for wear, damage, hardening, or cracks. Replace all seals, gaskets, and O-rings.

8. Clean filter bowl and filter gasket surfaces of filter head assembly with diesel fuel or a similar
solvent that will not harm gaskets.

9. Install filter bowl assembly with a new filter element, if necessary, and new seals. Install and
tighten filter bowl drain plug, and loosely install vent plug into vent port in filter head assembly.

10. Open valves in fluid system that were closed in step 2 of this procedure. If necessary, activate the
system pump motor to provide fluid flow into filter assembly. Should fluid seepage occur, tighten
filter assembly vent plug.

Dispose of contaminated fluids, in accordance with EPA and local

environmental regulations.

11. Wipe up any spilled fluid prior to restoring the TM2500 MGTG set to service. Check filter
assembly for leaks. Eliminate leaks by tightening loose fittings. Confirm manual drain valve is
closed.

12. Restore power to the pump motor by turning switches to their normal settings at the MCC.

20100 2-2-9
2433123 Orig
Chapter 2 GE Energy
Section 2

CO2 Weight and Pressure Check

The following procedure outlines the method to check the weight and pressure of the CO2 in each bottle. For
liquid level indication, charts, and tables referenced in this procedure, see the Wilson Fire & Gas Protection
System Manual, CO2 Systems section, in Chapter 5 of this manual.

1. Use an accurate Fahrenheit thermometer to read and record the ambient temperature for use in
converting the CO2 level to a weight measurement, and determining the acceptable minimum CO2
pressure in each bottle.

2. To determine the CO2 level in each bottle, use the magnetic float/dipstick indicator as follows:

a. Remove the chained cap from the liquid level indicator at the top of the CO2 bottle.

b. Lift the level indicator dipstick upward, until a sharp magnetic tug is felt on the dipstick.

c. Read and record the level indicated at the interface between the dipstick and the fixture.

d. Push the dipstick back into the retainer and replace the cap.

3. Convert the level indication to pounds of CO2 as follows:

Note To convert the level reading to its equivalent pounds of CO2, see the conversion chart
attached to each new CO2 bottle. For further information, refer to the chart in the Wilson Fire &
Gas Protection System Manual.

a. On the left-hand side of the conversion chart, find the CO2 level recorded in step 2 of this
procedure.

b. Move across the chart to the ambient temperature point (as interpolated between the temperature
lines on the chart).

c. From the juncture of the line from the level reading to the temperature point, move downward to
the bottom of the chart and record the pounds of CO2 in the bottle.

d. If the CO2 weight is less than 95% of the original fill weight as stamped on the cylinder
nameplate, replace the cylinder with a fully filled and charged cylinder and send the old cylinder
to an authorized filling station for leak inspection, maintenance, and refill.

4. Check the CO2 cylinder charge pressure as follows:

a. Read and record the CO2 cylinder pressure at the manifold pressure indicator.

b. Refer to the Wilson Fire & Gas Protection System Manual, and compare the indicated pressure
with the minimum pressure for the ambient temperature.

c. If the pressure is below the limit, replace the cylinder with a fully filled and charged cylinder,
and send the old cylinder to an authorized filling station to be re-superpressurized and leak
tested.

2-2-10 20100
Orig 2433123
GE Energy Chapter 2
Section 2

REQUIRED LUBRICANTS AND CONSUMABLES

Turbine Lube Oil

The turbine engine requires lubricating oil conforming to MIL-L-23699 or MIL-L-7808. This is a synthetic
oil. A list of oils meeting these specifications appears in Table 2.4, Required Lubricants and Consumables,
under Turbine Lube Oil.

Generator Lube Oil

The generator lube oils listed in Table 2.4 have been recommended by FKI Rotating Machines for their
turbine-driven generators. Contact FKI Engineering Department for alternate oils.

Hydraulic Fluid

The hydraulic system requires fluid meeting the requirements of MIL-H-17672 and ISO-VG46. A mineral-
based, premium, anti-wear hydraulic oil is supplied from the factory. The prime factor in the selection of
hydraulic fluid is the oil temperature extremes that will be experienced in service. These extremes will
govern the selection of a hydraulic fluid with the most suitable temperature/viscosity characteristics. When
considering the suitability of a particular hydraulic fluid or for applications near the extremes of viscosity/
temperature limits, consult the fluid manufacturer. As a minimum, hydraulic fluids should fall within the
viscosity ranges listed in Table 2.4, Required Lubricants and Consumables. Some fluids complying with the
above specifications appear in Table 2.4 under Hydraulic Fluid.

20100 2-2-11
2433123 Orig
Chapter 2 GE Energy
Section 2

Table 2.4, Required Lubricants and Consumables

Specified Required
System Lubricant Address Quantity

Turbine Lube AeroShell Turbine Oil 500 Shell Oil Company 150 gallons
Oil 50 West 50th Street
New York, NY 10020

Caltex RPM California Texas Oil Corp.

Jet Engine Oil 5 380 Madison Avenue
New York, NY 10017

Mobil Jet Oil II Mobil Sales and Supply Corp.

Mobil RM 193 A-3 150 East 42nd Street
New York, NY 10017

Stauffer Jet II Stauffer Chemical Company

(Castrol 205) 299 Park Avenue
New York, NY 10017

Turbine Lube Chevron Research Company

Chevron Jet Engine Oil 5 555 Market Street
San Francisco, CA 94120

Amoco Jet II American Oil Company

500 North Michigan Avenue
Chicago, IL 60611

Sinclair Turbo S Type 2 Atlantic Richfield Co.

875 North Michigan Avenue
Chicago, IL 60611

Atlantic Richfield Co.

Union Bank Building
P.O. Box 2679
Los Angeles, CA 90054

Exxon Turbo Oil 2380 Exxon Co., USA

P.O. Box 2180, Room 2455
Houston, TX 77252-2180
(713) 656-5949

2-2-12 20100
Orig 2433123
GE Energy Chapter 2
Section 2

Table 2.4, Required Lubricants and Consumables (Cont)

Specified Required
System Lubricant Address Quantity

Generator Lube Caltex Regal R & 0.32 California Texas Oil Corp. 215 gallons
Oil 380 Madison Avenue
New York, NY 10017

Castrol Perfecto N.A. Light Stauffer Chemical Company

299 Park Avenue
New York, NY 10017

Mobil DTE Light Mobil Mobil Sales and Supply Corp.

DTE 13 150 East 42nd Street
New York, NY 10017

Shell Lowtherm 25 Shell Oil Company

Shell Turbo T.32 50 West 50th Street
New York, NY 10020

Hydraulic Fluid Viscosity Ranges

Maximum at Startup 4600 sSu (1000 cSt)

Normal Operating 66464 sSu (12100 cSt)

Range

Optimum Operating 81141 sSu (1630 cSt)

Range

Minimum Acceptable 60 sSu (10 cSt)

ARCO Duro AW-46 Atlantic Richfield Co. 40 gallons

Union Bank Building
P.O. Box 2679
Los Angeles, CA 90054

Texaco Rando HDAZ-32 Texaco Incorporated

(New York Air Brake Start 2000 Westchester Avenue
Motors Only!) White Plains, NY 10650

Mobil DTE 25 Mobil Sales & Supply Corp.

150 East 42nd Street
New York, NY 10017

Exxon Nuto H 46 Exxon Co., USA

P.O. Box 2180, Room 2455
Houston, TX 77252-2180
(713) 656-5949

20100 2-2-13
2433123 Orig
Chapter 2 GE Energy
Section 2

These oils are not to be considered the only ones that may be used. Refer to the pertinent vendor material
contained in Chapter 5 of this manual.

Oil companies reserve the right to review their specifications periodically. It is essential and the
customers responsibility, therefore, to verify oil specifications with the local oil supplier.

2-2-14 20100
Orig 2433123
GE Energy Chapter 2
Section 2

This Page Intentionally Left Blank

20100 2-2-15
2433123 Orig
Chapter 2 GE Energy
Section 1

The most significant item of these scheduled inspections is a turbine borescope check, which provides
specific information on the condition of the engines compressor and hot-gas path. The turbine has a number
of ports specifically located to facilitate borescope inspections. It is standard practice to monitor the
condition of internal parts and schedule on-condition maintenance intervals based on borescope inspections.

Overall maintenance is divided into three basic levels according to the level of complexity and shop
capability.

On-Site External Maintenance - Level I

This is the simplest level of maintenance and it encompasses the following two categories:

Preventive Maintenance: Tasks that are scheduled on the basis of equipment run hours or
calendar time.

Corrective Maintenance: Tasks that are unscheduled and performed to correct a malfunction.

On-site external maintenance includes all work on the outside of the equipment, plus scheduled inspections
of turbine generator, cleaning (water wash), and changeout of gas generator turbine or components of driven
equipment (when necessary).

Off-Site Maintenance - Level II (Medium Shop Repair)

This level of maintenance includes a complete teardown and rebuild of major components of the turbine
generator.

Off-Site Maintenance - Level III (Extensive Shop Repair)

This scope of work provides for all levels of maintenance, plus a complete repair of gas generator, power
turbine, or driven equipment parts. A test cell is required for a Level III facility.

Maintenance Schedule

Normal maintenance of the GE AEP turbine-powered package during the initial 3 years of operation (at
8000 hours per unit per year) will require only a weekly visual inspection of turbine and driven equipment
exteriors. None of these inspections or tasks requires equipment removal or disassembly.

The weekly inspection will require approximately one man-hour while the unit is in operation. The
scheduled maintenance tasks are recommended at 6- and 12-month intervals, and can be performed in one
8-hour shift, requiring approximately 16 man-hours for the set of tasks on the turbine.

Note Do not fill the turbine lube oil reservoir past two-thirds full while the turbine is running.
Overfilling will result in runover when unit is shut down.

Required Lubricants and Consumables

See Table 2.4, Required Lubricants and Consumables, in Section 2 of this chapter for recommended list of
lubricants and fluids used on the turbine-generator set. For acceptable equivalents, see vendor-provided
instructions in Chapter 5.

2-1-2 20100
Orig 2433123
GE Energy Chapter 2
Section 3

Chapter 2, Section 3

Troubleshooting

Note Vendor literature referenced on this page is contained in Chapter 5 of this manual.

PRIME MOVER

Troubleshooting procedures for the prime mover are contained in Volume I of the General Electric On-Site
Operation and Maintenance for General Electric TM2500 G Series and P Series Gas Generators and
Gas Turbines, GEK- 97310. For ancillary equipment, control system, and related troubleshooting, refer to
Chapter 4 in this manual.

GENERATOR

Troubleshooting procedures for the FKI AC generator appear in the FKI Operating Machines Installation,
Operation & Maintenance Manual. Refer to Section 7, Fault Finding, of the FKI manual for
troubleshooting information.

ANCILLARY EQUIPMENT

Troubleshooting information for various external systems of the turbine-generator unit can be found in
specific vendor literature and the GE Aero Energy Products drawings in Chapter 4.

20100 2-3-1
2433123 Orig
Chapter 2 GE Energy
Section 3

This Page Intentionally Left Blank

2-3-2 20100
Orig 2433123
GE Energy Chapter 2
Section 4

Chapter 2, Section 4

Repairs and Adjustments

PRIME MOVER

Repairs

Repairs of the LM2500 Turbine Engine are covered in the GE On-Site Operation and Maintenance Manual,
GEK-97310, Volume II, provided as part of Chapter 5 of this manual.

Adjustments

Except for the variable stator control, very few adjustments are necessary for the turbine engine. For
adjustment to the variable stator control, see GE On-Site Operation & Maintenance Manual, GEK-97310,
Volume II.

GENERATOR

Repairs

Procedures for repairing the FKI BDAX62-170ER AC generator can be found in the FKI Installation,
Operation & Maintenance Manual, provided in Chapter 5.

Adjustments

A potential adjustment item is pilot exciter remagnetization, described in Section 8 of the FKI manual. No
other periodic adjustments of the generator are necessary.

ENGINE TO GENERATOR ALIGNMENT

General
The engine and generator rotor shafts must align with each other before operation. Accurate alignment
extends the service life of the bearings in both machines and ensures efficient, reliable operation. Under
normal operating conditions, optimum axial alignment reduces or eliminates loading on the thrust
bearings in both machines. Laser alignment uses optical measurement techniques that provide unequaled
accuracy and repeatability. Optical measurement reduces many of the common errors associated with
mechanical alignments that are affected by gravity. Technicians can quickly see graphical representations
of the current alignment status and real-time effects of adjustments made to the turbine-generator unit.
Professional reports can easily be generated by simply downloading laser alignment results to most
printers.

Note Engine to generator alignment is accomplished during setup of the MGTG, and complete
instructions are provided in the Installation Manual for that purpose. Alignment procedures are
repeated here in the event re-alignment becomes necessary at some point between setup and teardown,
providing trailer leveling or docking have not been disturbed. Otherwise, perform appropriate portions
of the main trailer set up procedure in IT120 of the Installation Manual before proceeding with the
engine to generator alignment described here.

20100 2-4-1
2433123 Orig
Chapter 2 GE Energy
Section 4

Adjustment Process

The adjustment process starts with the measurement of existing shaft alignments between the generator
and engine, and movement of the engine into position to correct misalignment. Measurements are made
with a ROTALIGN laser alignment system to identify parallel and angular offset values of the movable
engine shaft as compared to the stationary generator shaft. Refer to Figure 4.1, Parallel and Angular
Offset. All adjustment is accomplished by moving the engine platform with jackscrews, wedges, and
shims, as required to align the engine shaft to the stationary generator shaft Optimum offset and angular
alignment exists when the axes of engine and generator rotors coincide at normal operating temperatures.
In the following procedures, the term forward refers to the direction toward the bellmouth end of the
main trailer.

GE Aero Energy Products (GE AEP) Technical Services has the required equipment and personnel
familiar with conducting laser alignments. Please contact your GE AEP Technical Services regional
service office for assistance in contracting their services.

Axial Alignment

Axial loading on the engine thrust bearings can be greatly reduced or eliminated by ensuring that the
engine and generator rotors remain separated at operating temperatures. Incorporate proper separation by
installing the coupling with a prestretch that will allow its flexible diaphragm packs to reach their
unflexed, unloaded states through normal thermal expansion. The forward thrust capacity of the power
turbine thrust bearing is approximately one-third of that in the aft direction. Therefore, to avoid
overloading the bearing in the forward position, use the forward thrust position as a datum point and
calculate the coupling prestretch as equaling the algebraic sum of all thermal expansions from engine cold
to engine hot (fully loaded) conditions.

Proceed with axial alignment as follows:

1. Position turbine shaft fully forward.

2. Position generator shaft at the mid-point of its axial travel.
3. Install coupling extension removed for transport (Figure 4.2) and secure turbine end of extension to
the flexible coupling. At the generator end of the extension, temporarily insert undersized bolts or
metal rod through at least two of the extension and generator flange bolt holes. Bolts or metal rod
should be of sufficient diameter to prevent any sagging at the joint, while allowing the extension to
move axially in relation to the generator flange.
4. Using a feeler gauge, measure the gap between the face of the generator coupling flange and the
extension flange. This measurement (prestretch) should equal .35 inch.
5. Adjust engine position with clevis fore and aft jacking screws to obtain the required .35 inch gap. If
required amount of adjustment exceeds the range of the jack screws, loosen generator mounting bolts,
and with jack screws in the center of their travel,. move generator axially with a hydraulic jack until
gap is near .35 inch.
6. Tighten generator-mounting bolts and final adjust gap to .35 inch with jack screws.
7. Secure extension flange to generator shaft flange.

Repeat this procedure as necessary until the reading remains unchanged after tightening all fasteners.

2-4-2 20100
Orig 2433123
GE Energy Chapter 2
Section 4

Preparations for Laser Alignment

Prepare engine and generator for alignment by disconnecting the engine exhaust diffuser to expose the
engine/generator coupling flanges. Access to the coupling can be attained through the access hatch on the
left side of the exhaust silencer trailer. The diffuser is heavy and will require two men to move the unit to
the rear and to install temporary support.

Laser Alignment

The only laser alignment system currently approved for use on all LM packages is ROTALIGN (a
registered trademark of Pruftechnic AG). ROTALIGN is preferred because of its features.

Use the information in this section in conjunction with the operating instructions provided with the
ROTALIGN laser tool, to perform laser alignment of the LM2500. Parallel offset refers to the amount of
misalignment between two shaft centerlines at the load flange. The direction of this parallel offset is
perpendicular to the load centerline (refer to Figure4.1, Parallel and Angular Offset). Angular offset
refers to the amount of separation between two flange faces at the load flange. Parallel and angular offsets
are specified in vertical and horizontal directions.

Figure 4.1, Parallel and Angular Offset

Tools and Equipment

Refer to Table 4.1, Recommended Tools and Equipment for Alignment, for a description of the tools and
equipment necessary to perform the alignment procedure. The tools and equipment are depicted in the
figures that follow this table.

20100 2-4-3
2433123 Orig
Chapter 2 GE Energy
Section 4

Table 4.1, Recommended Tools and Equipment

for Alignment

Quantity Description

1 Laser kit with 5-meter cable

1 Magnetic bolthole bracket (PN ALI.2.106)
1 Inside micrometer (STARRETT PN 128BZ) (optional)
1 Dial calipers, 0"6" (0.001" gradations)
1 Feeler gauge

Desired Parallel and Angular Offsets

Table 4.2, LM2500 Desired Parallel and Angular Offsets, lists the desired parallel and angular offsets and
tolerances for the TM2500 package. These values are specified at the load flange. The correct viewing
direction is looking at the load from the turbine. The position of the turbine with respect to the load is
defined as follows: parallel (+) with the turbine centerline either above or right of the load centerline;
and angular (+) with the flanges open at either the top or the right side. (Mils is 1/1000th of an inch
[0.001"]).

Table 4.2, LM2500 Desired Parallel and Angular Offsets

TM2500 Vertical Horizontal

Offset Offset

FKI Generator
Parallel Angular Parallel Angular

Mils Mils Mil Mils

s
Value/Tolerance -77 5 -7 5 0 5 0 5

Re-alignment tolerance 7 6 7 6

Laser Alignment Procedure

Perform the following steps to measure and adjust parallel and angular offset values of the turbine engine
rotor shaft in relation to the generator shaft. Measurements are made from the stationary load (generator)
flange, to the turbine coupling flange.

2-4-4 20100
Orig 2433123
GE Energy Chapter 2
Section 4

Note Rotate generator shaft with chainfall and strap from bracket provided. To ensure readings are
accurate, relieve tension on shaft and allow it to settle before each reading.

1. Attach ROTALIGN sensor to rear face of turbine coupling flange with magnetic bracket. Position
sensor for line-of-sight alignment with the laser through the coupling tunnel.

2. Attach ROTALIGN laser at the forward face of the shaft coupling flange with magnetic bracket.
Position and test line-of-sight alignment with the sensor.

3. Connect ROTALIGN computer, select DIM Mode, and enter the following values: Refer to
Figure 8, Preset Dimensions and Values.

a. Coupling diameter = 16.375

b. Distance to left machine = 42
c. Distance to right machine = 102
d. RPM = 3600 RPM
c. Machine 1 distance left to right foot = 118
g. Machine 2 distance, left to right foot = 143

4. Set tool to Multipoint Mode and take from 20 to 30 readings through 360 shaft rotation.
Consistent degrees of shaft rotation between readings are not critical.

5. Select Coupling Mode to read shaft offset and angular misalignment values Repeat step 4 and
compare results for consistency. If readings are inconsistent, identify cause and repeat step 4.

6. Select Move Mode and adjust turbine platform as required to correct turbine shaft parallel and
angular misalignment. Adjust the engine position by making equal shim changes at all engine
platform mount locations.

7. Replace and secure engine exhaust diffuser when alignment is complete.

20100 2-4-5
2433123 Orig
Chapter 2 GE Energy
Section 4

Figure 4.2, Preset Dimensions and Values

2-4-6 20100
Orig 2433123
GE Energy Chapter 2
Section 4

ANCILLARY EQUIPMENT

Repair

Information for repair of the subsystems and components of the unit can be found in Chapter 5, Vendor
Data, and Chapter 4, Drawings of this manual.

Adjustments

The following adjustments should be made on an on-condition schedule or as needed to maintain equipment
in proper working order.

1. Instruments and Indicators Instruments and indicators may need to be calibrated more frequently
than listed in Table 2.3, Ancillary Equipment Maintenance Schedule, in Section 2 of this chapter. If
a reading on the indicator is high or low and all other indications confirm proper operation,
recalibration of suspect indicator is in order.

2. Transducers and Probes Positioning of probes may need to be adjusted if indications appear to
fluctuate or vary from the norm. Refer to proper vendor data contained in Chapter 5 of this manual.
Also refer to GE AEP Flow and Instrument Diagrams (F&IDs) contained in Chapter 4 for set points
of electrical instrument probes.

3. Pressure and Temperature Controllers Adjustments may need to be made on various pressure
and temperature controllers to keep pressures and temperatures within normal range. Refer to GE
AEP F&IDs contained in Chapter 4 for set points and to Chapter 5 for details of the various
controllers.

4. Equipment Alignment Realignment of equipment may need to be performed to compensate for

normal wear. Excessive vibration or noise will generally indicate when this should take place. If
vibration levels become too great, it is recommended that an alignment check be made. Settling of
the unit or foundation can adversely affect machinery alignment. Refer to Chapter 5 for tolerances
of various vendor items.

5. Air Filtration System The air filtration system is designed to operate for extended periods
between maintenance intervals. The turbine enclosure is equipped with a differential pressure
switch, which will trip an alarm on the turbine control panel in the auxiliary trailer control house
when the air filtration system restriction reaches the point that maintenance is required.
Maintenance of the air filtration system shall be carried out in accordance with the instructions
provided by the air cleaner manufacturer, which are included in Chapter 5 of this manual.

20100 2-4-7
2433123 Orig
Chapter 2 GE Energy
Section 4

6. Control System The control system is designed to require little maintenance; however, there are
two areas in the control system that require regular maintenance to ensure proper operation. These
areas include the battery banks, with their attendant battery chargers, and the sensing switches,
transducers, senders, thermocouples, and other sensing devices that are employed to monitor the
operation of the units.

7. Battery Banks The battery banks require periodic testing and replenishment of electrolytes, and
inspection and cleaning of battery terminal connections and battery cases. The float-and-equalize
voltage settings of battery chargers must also be checked and adjusted, if necessary. Maintenance
procedures and recommendations for DC power systems are provided by the battery and battery
charger instruction manuals included in Chapter 5.

SPECIAL TOOLS

There is a requirement for special tools to provide Level I and Level II maintenance activities. These tools
are listed in Table 4.3, Level I Maintenance Tools, and Table 4.4, Level II Maintenance Tools, and are
recommended for customer-performed maintenance.

Calibration Equipment

Refer to Table 4.5, Test and Calibration Equipment Required for Calibrating the Control System Sensing
Devices, for a complete listing of special tools and equipment required for calibrating the control system
sensing devices. Calibration equipment is not provided by GE AEP. This list is to aid the purchaser in
procuring the proper calibration equipment.

Equipment listed in Tables 4.3, 4.4, and 4.5 may not be provided by GE AEP in the basic scope of supply.
Some of the equipment listed is not essential, but is recommended for ease of service. Selected additional
items may be purchased from GE AEP.

2-4-8 20100
Orig 2433123
GE Energy Chapter 2
Section 4

Table 4.3, Level I Maintenance Tools

Nomenclature Quantity

Gauge, Immersion Igniter Plug 1

Wrench Set, Air Tube Coupling 1
Sling, Gas Generator/Turbine Horizontal Lifting 1
Adapter, Borescope Drive 1
Wrench, Stator Vane Speed Sensor 1
Wrench, Fuel Nozzle 1
Borescope Set 1

Table 4.4, Level II Maintenance Tools

Nomenclature Quantity

Set, Jackscrew 1
Puller, No. 5 Bearing Inner Race 1
Wrench, High-Pressure Turbine Locknut 1
Stand, Vertical High-Pressure Turbine, Rear Main 1
Fixture, Lift High-Pressure Turbine, Rear Horizontal 1
Wrench, SpannerOil Tube 1
Fixture, Lift Stage No. 1 High-Pressure Turbine Nozzle 1
Puller, No. 5 Bearing Retaining Ring 1
Fixture, Combustor Liner Horizontal Lifting 1
Wrench, Spanner - No. 5 Bearing Retaining Nut 1
Lift Eye, High-Pressure Turbine, Rear Aft Section 1
Pusher, No. 5 Bearing Inner Race 1
Wrench, Spanner, Hand Run-up 1
Tool, Install/Remove Damper Sleeve 1
Pins, GuideStage No. 2 High-Pressure Turbine Nozzle 1
Adapter, Wrench 1

20100 2-4-9
2433123 Orig
Chapter 2 GE Energy
Section 4

Table 4.5, Test and Calibration Equipment Required for Calibrating the Control System
Sensing Devices

Any test procedure that calls for rotating machinery to be in

operation shall not be attempted without direct supervision by GE
Aero Energy Products service technicians and/or representatives.
Failure to comply with this warning could result in the equipment
warranty being voided.

Note Test and calibration equipment with specifications equal to or better than equipment listed
here may be substituted. Refer to manufacturer-provided publications, included in Chapter 5 of this
manual, for equipment specifications.

Nomenclature Part No. Source/Manufacturer

Deadweight Tester (for testing 23-1 (or equivalent) Chandler (or equivalent)
pressure switches)

Hot-Oil Bath, electrically heated, Various Various

with adjustable thermostatic temp-
erature control, oil agitator, and
calibrated thermometer (for testing
temperature switches)

Digital Multimeter 8021B Fluke

(two required) 177 Keithley

AC/DC Power Supply 6234A Hewlett-Packard

(two required)

Function Generator/ T86671 Woodward Governor Company
Frequency Counter

Volt-ohmmeter, 260 Simpson

20,000 ohms/volt

Oscilloscope, Dual-Channel 15 2213A/2215A Tektronix

MHz

43027 Conductive PCB Shunt Bar 4962-005 Woodward Governor Company
(two may be required)

Antistatic Protective Bag 4951-019 Woodward Governor Company
(two may be required)

2-4-10 20100
Orig 2433123
GE Energy Chapter 2
Section 4

Table 4.5, Test and Calibration Equipment Required for Calibrating the Control System
Sensing Devices (Cont)

Nomenclature Part No. Source/Manufacturer

Jumpers, with insulated alligator Various Various

clips

Ionization Detector Sensitivity SCU-9 Pyrotronics Pyr-A-Larm

Checker

Adapter Kit SAU-2 Pyrotronics Pyr-A-Larm

Megohmmeter, 21-158 Biddle (or equivalent)

500 V5 kV

20100 2-4-11
2433123 Orig
Chapter 2 GE Energy
Section 4

This Page Intentionally Left Blank

2-4-12 20100
Orig 2433123