LM2500 Maintenance & Troubleshooting
LM2500 Maintenance & Troubleshooting
LM2500 Maintenance & Troubleshooting
Troubleshooting
Fall 2006
Restart Procedure
Fault is fully understood & restart can be safely initiated
Restart within 10 minutes after high pressure rotor speed
decreases below 300 RPM
Do not restart for 4 hours if 10 minutes have elapsed
Consult latest revision of the O&M manual for detailed restart
procedure
Following protective functions require resolution before restart
attempt is made
Vibration alarm/shutdown, Fire system shutdown, Lube oil supply
pressure low alarm/shutdown, Lube scavenge alarm/shutdown, Over
speed alarm/shutdown, Lube filter pressure drop alarm/shutdown,
Enclosure high combustible gas level shutdown, Lube scavenge
pressure alarm, Chip detector alarm, Start system failure, Fail to crank
7
indication, and Stall detection shutdown
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Oil Leaks Troubleshooting
Verify consumption NO
Continue Operation
High consumption?
YES
Perform visual inspections as follows:
1. External engine
2. Package supply & scavenge system
3. Overboard drain system
4. Inlet & HPC through stage 6
5. Engine exhaust area and drain
NO NO YES
Continue Operation
NO YES
Go to B Overboard T/S
Continue Operation
Check A/B ejector for suction and pressurization .. 4-6 Replace L&S pump with 6 element
PSIG. Is suction and pressure OK? pump Monitor consumption
YES NO
Remove A-sump and AGB scavenge Clear obstruction or Replace No. 3 A/O seal
lines and check for obstructions in replace ejector
lines and screens
NO
Remove D-sump vent piping and check YES Clear obstructions and monitor oil
for obstructions. Obstructions Found? consumption
NO
NO
YES
Check A/O separator discharge piping for YES Clear obstruction and
obstruction, including flame arrester. Obstruction? monitor consumption
NO
Replace L&S
pump
NO
1. Remove B-sump frame piping (if installed) from engine vent horn NO Check vent piping for obstructions.
2. With engine at idle, check for heavy oil mist Obstructions found?
Heavy oil mist?
NO
YES YES
Go to E
NO YES
YES
Replace ejector and Fix leaks
monitor consumption
Remove B-sump scavenge system piping and check YES Clear obstructions and
for obstructions, including screen. Obstructions? monitor consumption
NO
Did a large quantity of oil drain from sump YES Replace L&S and
when scavenge line was removed? monitor consumption
NO
1. Remove C-sump frame piping (if installed) from engine vent horn NO Check vent piping for obstructions.
2. With engine at idle, check for heavy oil mist Obstructions found?
Heavy oil mist?
NO
YES YES
Go to E
NO YES
YES
Replace ejector and Fix leaks
monitor consumption
Remove C-sump scavenge system piping and check YES Clear obstructions and
for obstructions, including screen. Obstructions? monitor consumption
NO
Did a large quantity of oil drain from sump YES Replace L&S and
when scavenge line was removed? monitor consumption
NO
24 24
23 23
22 22
C /D E je c to r D is c h a rg e P re s s u re , P S IA
A /B E je c to r D is c h a rg e P re s s u re , P S IA
21 21
20 20
19 19
18 18
17 17
16 16
15 15
5000 6000 7000 8000 9000 5000 6000 7000 8000 9000
Note: NOx present in ambient air goes through unaltered while CO and UHC may be chemically reduced
26 GE Proprietary - Subject to Restrictions on Cover Page
Types of Emission Product
Particulate
Consists of particles of dirt and heavy metals like
Sodium, Potassium, Ash, Vanadium etc usually
present in the atmosphere or fuel
Usually no mechanism to reduce these except
maintaining fuel and air quality & filtration
Soot/Carbon
Usually a result of incomplete or inefficient burning of
fuel
Sulfur Oxides SO2/SO3
Usually a result of sulfur content in fuel.
30 GE Proprietary - Subject to Restrictions on Cover Page
Controlling Other Products of Emission
CO2
Causes Green House effect
A product of chemical reaction of carbon from fuel
and oxygen from air
Amount of CO2 is directly proportional to amount of
fuel
More power >> more fuel >> more CO2
Same power but worse thermodynamic efficiency >> more
fuel >> more Co2
Inversely proportional to thermal efficiency of gas turbine
SAC Combustors
DLE Combustors
engine exhaust
SCR=Selective Catalytic Reduction Water flows in
secondary manifold
Could bring NOx/CO down to 1-5 This sketch applies to Duel fuel water
ppm levels
injected system. Hardware design for
injecting water or steam varies for gas
only, liquid only or duel fuel applications
Gas Fuel
Methane
Ethane
Butane
And higher .
Higher hydrocarbon chains are generally heavier and
will result in lower Wobbe number (a quantity
indicative of heating value to fuel density ratio)
Fuel Quality
Most important requirement is to have adequate level
of heating value which is controlled by allowing
Wobbe number from 40-60 (Wobbe number is
indicative of heating value to density ratio)
Low Wobbe number will require increased fuel flows which
may
Impact fuel nozzle pressure drop hence cause acoustics
Limit power due to Max fuel limitations
High Wobbe # will reduce fuel flow to water/steam ratio
May cause acoustic due to low fuel nozzle pressure
drop
Fuel temp. may be increased to reduce Wobbe Number
38 GE Proprietary - Subject to Restrictions on Cover Page
Gas Fuel Quality
Water Content
Fuel must be dry. Any water content may cause icing
situation in the fuel system even at high temperatures (due
to high fuel pressure)
Contamination
Heavy metal contamination (like rust) may cause plugging
up of the fuel nozzles
Site fuel filtration is needed
Nozzles are equipped with screen (last chance filter) which
may catch large size contamination
Liquid Fuel
Diesel, Naphtha ,,,
Liquid fuel in DLE combustors usually are more
reactive, hence has potential for higher flame
temperatures
Fuel Quality
Diesel fuel typically has more Sulfur, Sodium,
Potassium contents which may cause corrosion
Hence hardware life with liquid fuel is typically much
lower
40 GE Proprietary - Subject to Restrictions on Cover Page
Some Important Suggestions for NOx control
SAC Combustors
For reduced NOX, increase water/steam injection
If CO is high, you may be injecting too much water/steam
High Water/Steam injection may also cause flame out
High emissions may be caused by fuel nozzle wear
High emission levels may also be caused by quality of fuel
Fuel quality may also impact hardware life
Clean fuel is required to avoid fuel nozzle fouling
Any water in gas fuel may cause freezing in the fuel system
DLE Combustors
Mapping process is the main tool to maintain appropriate
emission levels
High NOx or CO may be in one or more of the three rings
To reduce NOx, Flame temperature of the ring producing high
NOx must be reduced
To reduce CO, the flame temperature of the ring producing
high CO must be reduced
Dirty or fouled pre-mixers will cause high emission that may
not be reduced via mapping
Fuel quality is important in keeping fuel pre-mixers in good
health
42 GE Proprietary - Subject to Restrictions on Cover Page
Engine Interface Orientation
Electrical System:
Wrong Execution
M4
47 GE Proprietary - Subject to Restrictions on Cover Page
LM2500 Base & Plus Bolts and Dowels
M5
M4
48
Note: For Plus engine use SMO9726085; For Base engine use SMO0880415
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LM2500 Base & Plus
Note: This section is for Plus engine, but still good for Base engine.
49 GE Proprietary - Subject to Restrictions on Cover Page
LM2500 Base
E35
A9A
LM2500 Plus
50 GE Proprietary - Subject to Restrictions on Cover Page
Is the support-bracket for
bellmouth installed?
S34
Is any WW connection not
in use plugged?
E7
E12
Note:
52
Only Plus Engine; Base Engine NOT ring.
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LM2500 Base
VSV Control
IMPORTANT:
Check for lock
wire presence.
Cable NP code:
E46 & E47 RCO43953
E46 E47
L9
Valve Hydr. Supply*
Pad
A17
Connections
Usually for:
A17 - Fuel Pump
A19 - Starter
A14 - Hyd. Pump A19 A14
56 GE Proprietary - Subject to Restrictions on Cover Page
Lube & Scavange Pump Connections LM2500 Base & Plus
L7
L5
L2
L1
L4
L3
Check hoses if
twisted, crashed or
loose.
Check hoses if
Laying on GG
unsupported.
Check hoses if allow
GG expansion.
Check for leakages.
Check cables for
chasing and routing.
A12
LM2500 Base
60 GE Proprietary - Subject to Restrictions on Cover Page
LM2500 Base & Plus
Check 3 Flexible
Hose for chafing.
Note: In case, put
some protection
(as shown) or re-
route tubing.
Checkfor any
missing/broken
hardware.
Check if TGB
presents any
bumps.
Check all
external
hardware
(clevis, rod
end bearing,
etc.) for
broken or
missing
safety wires.
Check for
kinks, bends,
nicks..
65
-WP209 on GEK105054 for LM2500Plus SAC
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LM2500 Base
Plus Engine
67 GE Proprietary - Subject to Restrictions on Cover Page
LM2500 Base
Check actuator hydraulic lines for evidence of leakage.
Check for missing and/or broken hardware.
E1
Verify that:
- S.B. 153 has been applied (the upper
photo shows the old design).
- All the expandable bolts have been
changed every 4000 h as per IAD
S.L. 2500-I-01-04.
Ref Documents:
- S.B. 153 Rev. 4.
- S.L. 2500_01_03R1.
- S.L. 2500_01_04R1.
- S.L. 2500_99_06R1.
NEW
72 GE Proprietary - Subject to Restrictions on Cover Page
LM2500 Base & Plus
Check if tick
welding is in place.
E30B
Base Engine
E30A
Plus Engine
Plus Engine
74 GE Proprietary - Subject to Restrictions on Cover Page
LM2500 Base & Plus
PS3 (96CD-1/2)
Compressor Discharge Trnsmitter
Typical Connecton
shows on P&ID.
SAC
79 GE Proprietary - Subject to Restrictions on Cover Page
LM2500 Base & Plus
Note: Only DLE Version
Combustion Chamber
(Shield on CRF)
Refer always to
GEKs Manuals.
80 GE Proprietary - Subject to Restrictions on Cover Page
Premixer LM2500 Base & Plus
Note: Only DLE Version
Fuel Nozzle
Different type of Fuel Nozzle:
- gas only L31810G04
- dual fuel (A) L31809P09
- dual fuel (BC) L31809P10
- liquid only 9016M58P06
- gas/water L31809P08
- gas/steam L31957G03
- liquid/steam L31809P11
- liquid/water L31809P11
1 2 3
- dual steam L47449P01
Flame Detector
Support flame detector cable to
prevent
contact with other hardware.
4 Route properly FD cable to avoid any
chafing.
Tight properly FD onto FD support
bracket.
Note: Usually
the bolts for FD
are not
supplied with
GG.
FD Locations:
- 4:00 oclock.
10 - 10:00 oclock
85 GE Proprietary - Subject to Restrictions on Cover Page
LM2500 Base & Plus
Acoustic
Sensor Note: Only DLE Version
In case your Bently Nevada system is 3300 make sure the head scale of the
monitor is 10 psi PK-PK. If not do the following procedure:
POWER
C1
AMPLIFICATORE COM
FREQUENCY DI CARICA TO BENTLY NEVA
BENTLY NEVADA MONITOR
GENERATOR
FILT.OUT +
C2
FILT.OUT -
------- mV
V= Q/C
Where:
Q= misured charge in COULOMBS
C= condenser capacity in FARAD
The purpose is to simulate the charge to the amplifier in order to check the reading on the Bently Nevada monitor.
To do that, set the frequency using the generator to 600 Herz and than changing the amplitude we find the Volts (V) to apply to the
condenser in order to obtain the pressure in "psi" (to be read on B.N. monitor).
Carry out the pressure transducer check following the next table:
Repeat above steps until all values in the following table have been checked.
(1) 6 2 7.2
(2) 2 4 10.4
(3) 8 6 13.6
(4) 4 8 16.8
(8) 0 10 20.0
NOTES:
(1) The Vibrometer RSI signal conditioner should have been calibrated at the factory for a sensor with an output of 16 pC/psi peak and a range of 0 to 10 psi
peak-peak. This range has been used to determine the expected milliAmp level in the table above.
(2) Typically, OEMs use 4-20 mA outputs to their control system. The above Expected mA output levels have been provided for your convenience. If you
have a better way at the control system of determining the output level, feel free to use it!
D10
In General:
Check all external hardware
(pipes, hoses, etc.) for broken
or missing safety wires.
Check hoses if twisted,
crushed or loose.
Check for loose clamps and
brackets.
Check for any loose fittings.
90 GE Proprietary - Subject to Restrictions on Cover Page
HP Recoup LM2500 Base & Plus
In general:
(STRUTS)
6 5
95 GE Proprietary - Subject to Restrictions on Cover Page
LM2500 Base & Plus
Check hoses if
D5 twisted, crushed or
loose.
A13 Check hoses for
support.
Check hoses to
allow
for GG expansion.
Check for leakages.
Flame Temperature
Excessive NOx
NOx
B BC AB ABC
9000 4.5
8000 4
PX36 (psid)
6000 3
5000 2.5
4000 2
3000 1.5
2000 1
Constant
1000 0.5
PT Speed Demand
0 0
0 1 2 3 4 5 6 7
Time (s)
180 45
160
Blowout Parameter 40
140 35
120 30
WFQPERRCOR
TFLAMEPCT
100 25
80 20
60 15
40 10
20 5
TFLAMEPCT
0 0
0 1 2 3 4 5 6 7
Time (s)
3250
Outer Ring
780
3200
760
TFLIREF, TFLOREF (deg F)
3150
740
3100
720
T3 (deg F)
3050
700
3000 680
2950 660
2900 T3 640
2850
Inner Ring
620
2800 600
0 1 2 3 4 5 6 7
Time (s)
25 7900
Bleed
20 7800
15 7700
DWB36PCT
NGG
10 7600
5 BC 7500
0 7400
BC/2
-5 7300
Core Speed
-10 7200
30:53.0 30:54.7 30:56.5 30:58.2 30:59.9 31:01.6 31:03.4 31:05.1 31:06.8 31:08.6
1.2
WFNOZZPILFF
WFNOZINRFF
1.1
0.9
Pilot Ring
0.8
0.7
0.6
0.5
30:53.0 30:54.7 30:56.5 30:58.2 30:59.9 31:01.6 31:03.4 31:05.1 31:06.8 31:08.6
Cup
A Manifold
Staging (Outer
Outer Valve Cup Ring)
Metering
Valve Cup
Optional I/F Ten sets per engine
Pressure equalization
)(
orifice piping disconnected
B Manifold
Thirty per engine
FUEL SHUT- (Pilot Ring)
OFF Pilot Cup
Metering
Valve Optional I/F
)(
Staging
(Lean Blow-out
)( Valve Enhancement)
Fifteen per engine
Every other
Pilot Cup
Optional I/F
C Manifold
Staging
Valve (Inner
Inner Cup Ring)
Metering
Valve Fifteen sets per engine
Universal adjustments
TFLDMDJA Increase or decrease TFLMAX & TFLMIN
together by same amount
TFLMAXJA Increase or decrease only TFLMAX
TFLMINJA Increase or decrease only TFLMIN
TFLOSCHJA Increase or decrease outer ring temperature
TFLISCHJA Increase or decrease Inner ring temperature
ABAL ON/OFF (or MAPPING OFF/ON) Make ABAL active / inactive
CLEAR ABAL Remove any ABAL adjustment
Site specific
Tflame adjustment Increment Amount of change for one click of up or down
arrow
NetCon Data Logger Digital toggles to start, stop, and transmit DataLogs
Power adjustment Enables the mapper to change power level
Mapping enabled Permits mapping adjustments, usually password
protected