7255815 Princeton University LPT, Engine, and

Aero Energy
LM1600
LPT Installation, Engine Installation,
and Package Alignment
April 18th through 27th, 2014
For
Princeton University
ESN 751-533
Under
GE Oracle Project 7255815
Customer Representative: Eric Wachtman
GE Field Service Representative:
Matt Wilson
All technical recommendations and information contained in this report are based on GE manuals that have
been developed and approved for use with GE engines and parts that have been operated and maintained
in accordance with GE technical documentation and recommendations.
GE has no technical knowledge of, nor obligation for, non GE-approved parts and repairs. Accordingly, this
report is not intended to apply to non GE-approved parts and repairs, nor to any parts that may be directly
or indirectly affected by non GE-approved parts and repairs.
LM6-212 - V.4
Aero Energy
LM1600
Overview:
The purpose of this report is to document the maintenance with 751-533 that took place during the April
2014 outage. During this time the GG was removed, the LPT was replaced, and the engine was re-aligned
after a separate generator gearbox inspection.
Outage Data:
Engine Data:
ESN
Model
751-533
LM1600 SAC
Maintenance Data:
WP, SB, SL, PB, PL
Performed
WP 208 00
Engine Fired
Hours
Engine Fired
starts
Revision/manual reference
WP 500 00
LPT Module Removal and
Replacement
Gas Generator Handling
N/A
Package Hours
126,846.76
N/A
Package Fired Starts
736
Date
completed
18 April 2014
Comments
18 April 2014
Components Found Not Serviceable:
Detail Findings:
PAC Number (if available):
Notifications
(SM/CPM/PM/ENGR/SL or
FSRM):
Leaking CDP Flexible Hose.
N/A
CPM
Follow Up Action Items Engineering:
None
Follow Up Action Items SM/CPM/PM:
Order and ship to site flexible braided stainless steel hose for CDP System.
Hose Information:
1 1/4” Stainless Steel Hose x 16” long
MFG P/N 2796 32696-1
Reference Princeton F&ID 92904-B-2529 Revision 5
Item number on F&ID is M1305
Report completed by Matt Wilson
LM1600
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Aero Energy
LM1600
LPT Removal and Installation
General maintenance information for the work
done on both units:
- During reinstallation the original match-marks were
used from the November disassembly.
- The machined alignment pin was checked for proper
installation to make sure the LPT case was installed in
the correct orientation to the gas generator.
Seating check measurements were taken on both
GG’s and LPT’s prior to disassembly. The information on both units is provided in the following pages.
LPT match marks aligned
LPT nut installed and teeth engaged
LPT Module removed from engine
Alignment pin on LPT case
Report completed by Matt Wilson
LM1600
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Aero Energy
LM1600
LPT Module Seating Information:
Measurement A was taken on the LP shaft prior to LPT installation. This was
added to dimension X, the thickness of the seating flange on the low-pressure turbine to
ensure a proper seat. The actual thickness is within the calculated thickness tolerance of +/0.001”. The flange bolts on the LPT case were lubricated and torqued to 155 inch-lbs.
751-533
Replacement LPT Dim A
0.279"
Check without LPT Installed (Dim. X)
0.2745"
Check after LPT was replaced
0.554"
Calculated Drop
0.554"
LPT Identification Markings
The table below shows all identification marks found on the LPT modules that were swapped.
Customer LPT Module
Assembly
6042T05G06
Serial Number
GGM9E8W9
Assembly
Unknown
Serial Number
Unknown
Miscellaneous
60497T69P03
GATHDMLP
Example of identification marks found on LPT Rotors
Report completed by Matt Wilson
LM1600
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Aero Energy
LM1600
Engine Installation
Turbine View Right side
Turbine View Left side
Inlet inspected and free of debris
Mesh Screen Replaced
Floor checked and cleaned prior to start up
No leaks identified during crank/ leak checks
Report completed by Matt Wilson
LM1600
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Aero Energy
LM1600
Engine Installation
IGV’s and VSV’s inspected. No loose hardware, worn lever arms, guide pins or outer bushings identified.
Lease covered prior to can loading
Open lines and connections covered for shipment
Aft view of GG
Aft view of GG
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LM1600
Package Alignment:
TARGET
(+/- 0.010” Rim; +/- 0.005” Face)
RIM
FACE
0
0
0
0
0
0
0
0
AS FOUND
RIM
FACE
0
0
-5
+30
-5
+25
+5
-1
AFTER ALIGNMENT
RIM
FACE
0
0
-8
+8
-1
0
+2
+1
AXIAL DISTANCE
TARGET (+/- 0.010)
AFTER ALIGNMENT
42.000”
41.990”
42.000”
42.000”
42.013”
42.006”
42.000”
41.990”
Average: 42.000”
Average: 41.999”
Report completed by Matt Wilson
LM1600
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Aero Energy
LM1600
Start up details
Friday April 25, 2014
Replaced mesh FOD and completed final inlet inspection. LOTO removed for start up and
testing on gas. First start was fail to fire due to ignitor circuit breaker not being turned on.
Two more fail to fires occurred with gas valve operations appearing normal and fuel gas
pressure sufficient for start up. An investigation into the ignitor condition and ignition
system was completed with no faults identified. The system was restored and light off on
gas was successful by the end of the shift. During this run to full speed no load, it was
identified that PT speed probe #1 was not reading, and channel A on the PT vibration
accelerometer was also not reading. The unit was shut down and LOTO performed to
investigate. The speed probe and accelerometer connections were found to be secure.
Due to the high tempurature of the exhaust and back end of the PT no futher work was
conducted.
Saturday April 26, 2014
Replaced PT vibe accelerometer from customer stores for troubleshooting. PT speed
probe connections were removed cleaned and re-seated. LOTO removed for liquid fuel
start and successful on first attempt. Both PT speed pick ups and both Accelerometer
channels funtioning properly. No liquid fuel leaks observed. Unit syncronized and ramped
to 8MW for NOX water injection and then for transfer from liquid to fuel gas. No leaks
observed during NOX water injection. Transfer to fuel gas successful and unit ramped to
base load. Gas Detector alarm occurred at 15MW. Load was lowered until gas alarm was
cleared. Unit was then shut down and LOTO applied to check fuel system components
and connections for leaks.
On engine fuel tubes, nozzles, and manifold connections were found secure. No visual
damage to engine fuel components were observed. One flange just below the deck grate
at the main flexible fuel supply hose was found with three loose bolts. The gasket was
removed and replaced with a new 2” 600lb flex gasket and the bolts torqued to 100 lb/ft.
LOTO was removed with this second start of the day attempted on gas fuel. Light off on
gas was successful however the PT vibrations were high on this “hot start” and the unit
tripped and went into it’s normal programmed two stage start with the vibrations on the
PT being considerably lower on the re-start. Package gas detector alarms returned and
required another shutdown for further investigation.
LOTO installed and package gas detectors re-calibrated with no errors found. Floor deck
plate removed and the remainder of gas piping below the deck check for security with no
issues identified. Three more loose fitting connections were identified on the CDP purge
overhead piping which do tie into the main “on engine” gas manifold. Those connections
were secured and LOTO was removed for further operational testing.
Unit still with leak on detectors and tripped when trying to enter for leak check during
operation. Gathered supplies from local hardware store and customer shop to install
caps and blanks for fuel system static pressure check.
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Aero Energy
LM1600
Sunday April 27, 2014
Completed installation of caps and blanks. Pressurized gas fuel system with no leaks
identified on fuel tubes or hoses. Pressurized CDP side of gas fuel system and identified
flexible braided hose with leak.
A suitable replacement was identified onsite. It is made by Swagelock and is rated to
1200 psig. Minor change to the existing piping needed to be conducted as this new hose
was longer than the original hose. The new hose and piping changes were installed and
secured with the existing package bracket and clamp provisions. The damaged hose and
the old CDP pipe section have been stored on top of the jet engine parts lockers. The hose
can be scrapped but the piping will need to be saved for re-use when the replacement
hose arrives.
CDP Hose Leak
View of new hose and plumbing changes
Section of old CDP pipe to be saved until next visit
New hose with fittings prior to installation
Report completed by Matt Wilson
LM1600
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Aero Energy
Rated 1200 psig as Stamped by MFG,
LM1600
1” tube and elbow section used from customer parts
and adapted to fit to current CDP ceiling piping
configuration
The unit was succesfully started on gas with no further leaks or gas detector alarms for
the remainder of the day.
During this time, all operating perameters appear normal.
Phots of the run screen are pasted on the following pages.
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LM1600
Run Data Photos from HMI and Vibration Panel @ 7.3 MW on 27 April
Turbine Overview
Turbine Data 1
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Aero Energy
LM1600
Turbine Data 2
Water Injection Screen
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LM1600
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LM1600
Gas Generator Vibration
Power Turbine and Generator Vibration
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LM1600
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LM1600
Start up details
Monday April 28, 2014
Customer operations identified an oil leak causing smoking on the Power Turbine during
the evening of 4/27 and GE FS returned to the site on 4/28 to investigate. Customer
supported package cleaning and wipe down. Oil wetting was observed on overhead
piping for Power Turbine sump ventilation system. Further inspection revealed a cracked
doughnut seal on the 6” sump vent section. The complete section of piping has four such
seals and all were replaced as a precaution. The walls and floor areas were wiped down
and a visual inspection of turbine oil connections with no other immediate leak potential
identified.
The unit was started and operated to base load. During that time, visible oil debris could
be seen through the package observation doors and the unit was watched through these
ports to attempt to find the remaining leak. During this run, a loose flange bolt was
identified on the forward LPC flange. The loose bolt location was too low to the Accessory
Gearbox to enter and correct safelty and in a running condition. The unit was shut down
and the loose bolt corrected.
More package clean up during this shut down was conducted. During this shut down, oil
accumulation was identified on the right hand side of the package near the package
drain. The package drain valve was found open. This valve was close for the next start
under the assumption that oil was being drawn into the package and contributing to the
oil mess. More package, wall and turbine compartment floor cleaning was conducted
during this shut down as well.
The unit was restared and observed during the next test run to base load. During this
time, visible oil wetting continued to occur on the package observation windows. The
engine power was reduced and the fire system isolated so that a door could be opened
for a better viewpoint and observation into the remaining leaks. During this time, more oil
was identified on the right side floor and was cleaned up. Rags were affixed to broom
stick and oil drips were wiped from the package sealing and turbine piping as practical in
this running condition. The observation windows were cleaned.
The package doors were closed and the unit was ramped up to base load again. During
this ramp up, a leaking fitting was observed on the right hand side of the LPT on the CSump supply line and fitting. The was monitored for about 10 minutes and the unit shut
down and isolated for up close investigation and correction.
The IPB illustration on the nex page shows the location of the leak. The oil line supply to
the fitting was secure with no movement to the fitting. When the tube was disconnected
for further inspection, the positionable elbow became loose and it was identified that
while the line connection was secure it was clear that the secondary rentention nut on the
positionable elbow was not.
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LM1600
At low power and intial starts, the oil leak caused by the lack of security on this secondary
nut was not sufficient to notice until full power operation had been reached.
The unit was re-started and monitored for the remainder of the day and no further oil
leaks from this location were observed. During this run, package observation windows
remained clean and oil misting throughout the package had ceased. Due to the amount
of oil mess in the package from the combined sump vent and fitting leak, the package
ventilation louvers and ceiling were still accumulating oil while the package fans were
operating and an occasional drip from the ceiling would fall on the hot engine/ PT and
cause a brief smoking.
The unit ran overnight and Princetion operations monitored the unit with no other need to
shut down.
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Tuesday April 29, 2014
Unit continued to operate through the day and oil drips from the ceiling due to previous
leaks was subsiding. Leak location remained under observation for the day as well as
visual checks through observation windows for any new leaks.
Package was shut down in the afternoon for a final wipe down of walls, ceiling, floors and
ventilation louvres and was restarted and operated with no other issues for the remainder
of the day.
Wednesday April 30, 2014
Truck scheduled for tool pick up and representatives released.
END
Report completed by Matt Wilson
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