LM6000 PC O&M - GEK 105059 CHG 06
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Volume I
ON-SITE OPERATION AND MAINTENANCE MANUAL
FOR
GENERAL ELECTRIC LM6000® PC SERIES
GAS TURBINES
GE INDUSTRIAL
AERODERIVATIVE
GAS TURBINES
GE INDUSTRIAL AERODERIVATIVE GAS TURBINES
GENERAL ELECTRIC COMPANY
CINCINNATI, OHIO 45215-6301
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume I
Highlights of GEK 105059 Change 6
CHAPTER LOCATION DESCRIPTION OF CHANGE
Chapter 4 Paragraph 4-7 Updated
Chapter 6 Figure 6-10 Updated
Chapter 8 Paragraph 8-10.1 Added bullet point in step b.
Chapter 10 Paragraph 10-4 Updated entire Alarm column in Vibration Moni-
toring System table
Chapter 11 Paragraph 11-3.16 Updated step a.
Chapter 12 Paragraph 12-2.1 Added
Chapter 13 Table 13-1 Updated HPCR components in PN, Industrial
Life Limit (Cycles) and Kf columns and added
new component
Updated HPTR components in Kf column
Updated LPTR components in PN, Industrial Life
Limit (Cycles) and Kf columns
Appendix A All Editorial change only
Appendix A1 All Editorial change only
Appendix A2 All Editorial change only
Appendix A3 All Editorial change only
Appendix A4 All Editorial change only
Appendix A5 All Editorial change only
Appendix A6 All Editorial change only
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059
Volume I
ON-SITE OPERATION AND MAINTENANCE MANUAL
FOR
GENERAL ELECTRIC LM6000® PC SERIES
GAS TURBINES
GE INDUSTRIAL
AERODERIVATIVE
GAS TURBINES
GE PROPRIETARY INFORMATION
THE INFORMATION CONTAINED IN THIS DOCUMENT IS GE PROPRIETARY INFORMA-
TION AND IS DISCLOSED IN CONFIDENCE. IT IS THE PROPERTY OF GE AND SHALL
NOT BE USED, DISCLOSED TO OTHERS, OR REPRODUCED WITHOUT THE EXPRESS
WRITTEN CONSENT OF GE, INCLUDING, BUT WITHOUT LIMITATION, IT IS NOT TO BE
USED IN THE CREATION, MANUFACTURE, DEVELOPMENT, OR DEVIATION OF ANY
REPAIRS, MODIFICATIONS, SPARE PARTS, DESIGN, OR CONFIGURATION CHANGES
OR TO OBTAIN FAA OR ANY OTHER GOVERNMENT OR REGULATORY APPROVAL TO
DO SO. IF CONSENT IS GIVEN FOR REPRODUCTION IN WHOLE OR IN PART, THIS
NOTICE AND THE NOTICE SET FORTH ON EACH PAGE OF THIS DOCUMENT SHALL
APPEAR IN ANY SUCH REPRODUCTION IN WHOLE OR PART. THE INFORMATION
CONTAINED IN THIS DOCUMENT MAY ALSO BE CONTROLLED BY U.S. EXPORT CON-
TROL LAWS. UNAUTHORIZED EXPORT OR REEXPORT IS PROHIBITED.
ALL TECHNICAL DOCUMENTATION AND INFORMATION CONTAINED HEREIN 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 DOCUMENT 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.
COPYRIGHT (2013) GENERAL ELECTRIC COMPANY, USA
GE INDUSTRIAL AERODERIVATIVE GAS TURBINES
GENERAL ELECTRIC COMPANY
CINCINNATI, OHIO 45215-6301
15 May 2008
Change 6 15 August 2013
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume I GE Industrial AeroDerivative Gas Turbines
Foreword
This two-volume technical manual provides on-site operation instructions and general maintenance
procedures for the LM6000 Single Annular Combustor, PC Series, Gas Turbine. These instructions
are not intended to cover all details or variations in equipment, or to provide for every contingency
connected with installation, replacement, and maintenance. If more information is desired, or if prob-
lems arise which are not covered herein, contact General Electric Customer Service.
List of Effective Pages
Dates of issue for original and changed pages are:
Revision.......... 0 .......... 15 May 2008 Change .......... 4 .......... 15 August 2011
Change .......... 1 .......... 30 August 2008 Change .......... 5 .......... 15 August 2012
Change .......... 2 .......... 30 August 2009 Change .......... 6 .......... 15 August 2013
Change .......... 3 .......... 15 August 2010
Total number of pages in this volume is 398 consisting of the following:
Page No. Change No. Page No. Change No.
Title 6 10-1 to 10-106 6
A 6 11-1 to 11-44 6
i to xii 6 12-1 to 12-11/(12-12 Blank) 6
1-1 to 1-13/(1-14 Blank) 0 13-1 to 13-7/(7-8 Blank) 6
2-1 to 2-6 2 AppA A-1/(A-2 Blank) 0
3-1/(3-2 Blank) 0 App1 A-3 to A-16 3
4-1 to 4-14 6 App2 A-17 to A-23/(A-24 Blank) 3
5-1 to 5-53/(5-54 Blank) 5 App3 A-25 to A-28 4
6-1 to 6-18 6 App4 A-29 to A-30 4
7-1 to 7-31/(7-32 Blank) 5 App5 A-31 to A-34 4
8-1 to 8-28 6 App6 A-35 to A-36 5
9-1 to 9-5/(9-6 Blank) 0
A Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume I
Table of Contents
Page
Chapter 1 Introduction...................................................................................................... 1-1
1-1 Purpose and Scope of Technical Manual........................................................... 1-1
1-2 Arrangement and Use of Technical Manual ...................................................... 1-1
1-3 Notes, Cautions, and Warnings.......................................................................... 1-2
1-4 Changes to Technical Manual............................................................................ 1-2
1-5 Measurement Units ............................................................................................ 1-2
1-6 Glossary of Terms.............................................................................................. 1-7
1-7 Safety Precautions.............................................................................................. 1-7
1-7.1 Health Hazards .................................................................................... 1-7
1-7.2 Fire Hazards......................................................................................... 1-10
1-7.3 Compressed Air Hazards ..................................................................... 1-10
1-7.4 Heated/Chilled Part Hazards ............................................................... 1-10
1-7.5 Electrical Hazards................................................................................ 1-10
1-7.6 Paints and Finishes Hazards ................................................................ 1-11
1-7.7 Procedural Hazards.............................................................................. 1-11
1-7.8 Tooling Hazards .................................................................................. 1-11
1-7.9 Gas Turbine Operational Hazards ....................................................... 1-11
1-7.10 Environmental Hazards ....................................................................... 1-13
1-8 Special Inspections............................................................................................. 1-13
Chapter 2 Gas Turbine General Description and Model Summary ............................. 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 Model Summary .................................................................................. 2-1
2-2.3 Summary of Changes from the PA Model .......................................... 2-4
2-2.4 Standard and Optional Equipment....................................................... 2-5
2-2.5 Standard and Optional Instrumentation............................................... 2-5
Chapter 3 Gas Turbine Package....................................................................................... 3-1
3-1 Purpose and Scope ............................................................................................. 3-1
3-2 Package Description........................................................................................... 3-1
Chapter 4 Gas Turbine Assembly Description................................................................ 4-1
4-1 Purpose and Scope ............................................................................................. 4-1
4-2 General Description ........................................................................................... 4-1
4-2.1 Main Components................................................................................ 4-1
4-2.2 Engine Airflow .................................................................................... 4-7
4-3 Variable Inlet Guide Vanes................................................................................ 4-7
4-4 Low Pressure Compressor ................................................................................. 4-7
4-4.1 General Description............................................................................. 4-7
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Volume I GE Industrial AeroDerivative Gas Turbines
Table of Contents (Continued)
Page
4-4.2 LPC Rotor ............................................................................................ 4-8
4-4.3 LPC Stator............................................................................................ 4-8
4-5 Front Frame and Air Collector ........................................................................... 4-8
4-5.1 Front Frame.......................................................................................... 4-8
4-5.2 Bypass Air Collector ............................................................................ 4-9
4-6 High Pressure Compressor ................................................................................. 4-9
4-6.1 General Description ............................................................................. 4-9
4-6.2 HPC Rotor............................................................................................ 4-9
4-6.3 HPC Stator ........................................................................................... 4-9
4-7 Compressor Rear Frame ..................................................................................... 4-9
4-8 Combustion System............................................................................................ 4-10
4-8.1 General Description ............................................................................. 4-10
4-8.2 Single Annular Combustor................................................................... 4-10
4-8.3 Ignition System .................................................................................... 4-10
4-9 High Pressure Turbine ........................................................................................ 4-10
4-9.1 General Description ............................................................................. 4-10
4-9.2 HPT Rotor ............................................................................................ 4-10
4-9.3 Stage 1 HPT Nozzle ............................................................................. 4-11
4-9.4 Stage 2 HPT Nozzle ............................................................................. 4-11
4-10 Low Pressure Turbine......................................................................................... 4-11
4-10.1 General Description ............................................................................. 4-11
4-10.2 LPT Rotor ............................................................................................ 4-11
4-10.3 LPT Stator ............................................................................................ 4-12
4-11 Turbine Rear Frame............................................................................................ 4-12
4-12 Accessory Gearbox Assembly............................................................................ 4-13
4-13 Bearings.............................................................................................................. 4-13
4-14 Low Pressure Rotor Balance Piston System ...................................................... 4-13
Chapter 5 LM6000 PC Model System Descriptions ........................................................ 5-1
5-1 Purpose and Scope.............................................................................................. 5-1
5-2 Variable-Geometry Control System ................................................................... 5-1
5-2.1 VIGV System ....................................................................................... 5-2
5-2.2 VBV System ........................................................................................ 5-2
5-2.3 VSV System ......................................................................................... 5-4
5-3 Fuel Systems....................................................................................................... 5-4
5-3.1 Gas Fuel Systems ................................................................................. 5-4
5-3.1.1 Systems for Standard Natural Gas....................................... 5-4
5-3.1.2 System for Medium BTU Gas............................................. 5-5
5-3.2 Liquid Fuel Systems............................................................................. 5-6
5-3.3 Dual-Fuel System................................................................................. 5-17
5-3.4 Liquid Fuel Pump and Filter ................................................................ 5-17
ii Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
Table of Contents (Continued)
Page
5-3.5 Liquid Fuel Handling........................................................................... 5-18
5-4 Gearbox Assemblies .......................................................................................... 5-20
5-5 Starting System .................................................................................................. 5-20
5-5.1 GE Starter Usage ................................................................................. 5-22
5-5.2 Starter Duty Cycles.............................................................................. 5-22
5-5.2.1 Air and Gas Starters............................................................ 5-22
5-5.2.2 Hydraulic Starter................................................................. 5-22
5-5.2.3 Gas Turbine Airflow During Starter Operation.................. 5-25
5-6 Lube System....................................................................................................... 5-25
5-6.1 General Description............................................................................. 5-25
5-6.2 System Flows, Pressures, and Temperatures....................................... 5-28
5-6.3 Oil Specification .................................................................................. 5-28
5-6.4 Lube Subsystems ................................................................................. 5-30
5-6.4.1 Lube Supply Circuit............................................................ 5-30
5-6.4.2 Scavenge Oil Circuit........................................................... 5-30
5-6.4.3 Engine Drains ..................................................................... 5-30
5-6.4.4 Sump Vent Circuit .............................................................. 5-31
5-6.4.5 Lube and Scavenge Line Cooling....................................... 5-31
5-6.5 Sump Pressurization ............................................................................ 5-31
5-6.6 Oil Mixing ........................................................................................... 5-33
5-6.7 Oil Consumption.................................................................................. 5-33
5-7 Sensors and Indicating Systems......................................................................... 5-33
5-7.1 Speed Indication .................................................................................. 5-33
5-7.2 LP Rotor Speed.................................................................................... 5-34
5-7.3 HP Rotor Speed ................................................................................... 5-34
5-7.4 Vibration Sensors ................................................................................ 5-34
5-7.5 Temperature Sensors ........................................................................... 5-34
5-7.5.1 LPC Inlet Air Temperature (T2)......................................... 5-34
5-7.5.2 HPC Inlet Air Temperature (T25) ...................................... 5-34
5-7.5.3 HPC Discharge Temperature (T3)...................................... 5-34
5-7.5.4 LPT Inlet Gas Temperature (T48) ...................................... 5-34
5-7.5.5 Lube Supply and Scavenge Temperature ........................... 5-35
5-7.6 Pressure Sensors .................................................................................. 5-35
5-7.6.1 LPC Inlet Pressure (P2) ...................................................... 5-35
5-7.6.2 HPC Inlet Pressure (P25).................................................... 5-35
5-7.6.3 LPT Inlet Gas Total Pressure (P48).................................... 5-35
5-7.6.4 Additional Pressure Parameters .......................................... 5-35
5-7.7 Chip Detectors ..................................................................................... 5-36
5-7.8 Variable-Geometry Position ................................................................ 5-36
5-7.9 Flame Sensors...................................................................................... 5-36
5-7.10 Thrust Balance Control System........................................................... 5-36
Change 6 iii
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GEK 105059 LM6000 PC
Volume I GE Industrial AeroDerivative Gas Turbines
Table of Contents (Continued)
Page
5-8 Electrical System ................................................................................................ 5-36
5-8.1 Ignition System .................................................................................... 5-38
5-8.2 Cabling ................................................................................................. 5-38
5-8.3 Electrical Panels ................................................................................... 5-39
5-9 Bleed System ...................................................................................................... 5-39
5-9.1 Eighth Stage HPC Bleed ...................................................................... 5-39
5-9.2 HPC Discharge Bleed .......................................................................... 5-39
5-10 Engine Control Unit ........................................................................................... 5-39
5-11 Low Pressure Rotor Balance Piston System ...................................................... 5-39
5-12 Water-Wash System ........................................................................................... 5-39
5-13 Engine Airflow ................................................................................................... 5-41
5-14 Air System Tubing and Frame Strut Functions .................................................. 5-41
5-14.1 A-, B-, C-, D-, and E-Sump Vents ....................................................... 5-41
5-14.2 B- and C-Sump Pressurization ............................................................. 5-41
5-14.3 Balance Piston...................................................................................... 5-41
5-14.4 HPC Stage 8 Bleed............................................................................... 5-41
5-14.5 Compressor Discharge Pressure Bleed ................................................ 5-41
5-14.6 High Pressure and Low Pressure Recoup ............................................ 5-41
5-14.7 HPT Cooling ........................................................................................ 5-41
5-14.8 LPT Cooling......................................................................................... 5-41
5-14.9 Passive Clearance Control ................................................................... 5-41
5-15 SPRINT® System............................................................................................... 5-46
5-15.1 SPRINT® System with HP Injection Only.......................................... 5-46
5-15.2 SPRINT® Systems with LPC and HPC Inlet Injection ....................... 5-46
Chapter 6 Service and Support Requirements ................................................................ 6-1
6-1 Purpose and Scope.............................................................................................. 6-1
6-2 Shipping.............................................................................................................. 6-1
6-2.1 Engine Shipment .................................................................................. 6-1
6-2.2 Low Pressure Turbine Module Shipping ............................................. 6-2
6-2.3 Engine Shipping Container .................................................................. 6-2
6-2.4 Container and Engine Lifting............................................................... 6-2
6-2.5 Enclosure Shipping .............................................................................. 6-2
6-2.6 Highway Shipping................................................................................ 6-5
6-2.7 On-Site Transportation......................................................................... 6-5
6-3 Storage................................................................................................................ 6-5
6-4 Installation/Removal........................................................................................... 6-7
6-4.1 Installation/Removal Methods ............................................................. 6-7
6-4.2 Size/Weight .......................................................................................... 6-7
6-4.3 Engine Mount Attachments ................................................................. 6-7
6-4.4 Engine Power Output Shafts ................................................................ 6-9
iv Change 6
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume I
Table of Contents (Continued)
Page
6-4.5 Flange Interfaces.................................................................................. 6-9
6-5 Auxiliary Systems .............................................................................................. 6-11
6-5.1 Inlet System ......................................................................................... 6-11
6-5.1.1 Air Filtration ....................................................................... 6-11
6-5.1.2 Anti-Icing............................................................................ 6-13
6-5.2 Exhaust System.................................................................................... 6-13
6-5.3 Secondary Cooling Air ........................................................................ 6-14
6-6 Support Services ................................................................................................ 6-14
6-7 Maintenance ....................................................................................................... 6-16
Chapter 7 Installation and Startup................................................................................... 7-1
7-1 Purpose and Scope ............................................................................................. 7-1
7-2 General ............................................................................................................... 7-1
7-3 Installation.......................................................................................................... 7-1
7-4 Pre-Startup Inspections ...................................................................................... 7-1
7-5 Operational Checkout ........................................................................................ 7-30
7-6 Verification Test ................................................................................................ 7-31
Chapter 8 Engine Operation ............................................................................................. 8-1
8-1 Purpose and Scope ............................................................................................. 8-1
8-2 General ............................................................................................................... 8-1
8-3 Safety ................................................................................................................. 8-1
8-3.1 Gas Turbine Maintenance/ Inspection Precautions ............................. 8-2
8-4 Equipment Protection......................................................................................... 8-3
8-4.1 Inlet Cover ........................................................................................... 8-3
8-4.2 Bleed Air Collector Cover................................................................... 8-3
8-4.3 Exhaust Cover...................................................................................... 8-4
8-4.4 Electrical, Fluid, and System Interface Covers ................................... 8-4
8-5 Engine Protection............................................................................................... 8-4
8-5.1 Lubricating Oil .................................................................................... 8-4
8-5.2 Air........................................................................................................ 8-6
8-5.3 Fuel ...................................................................................................... 8-7
8-5.3.1 Gas Fuel .............................................................................. 8-7
8-5.3.2 Liquid Fuel.......................................................................... 8-7
8-5.4 Water ................................................................................................... 8-7
8-5.5 Steam ................................................................................................... 8-7
8-6 Records and Running Log.................................................................................. 8-8
8-7 Inlet/Enclosure Inspection.................................................................................. 8-8
8-8 Prestart Checks................................................................................................... 8-8
8-9 Motoring Procedures.......................................................................................... 8-9
8-9.1 Dry Motoring....................................................................................... 8-9
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GEK 105059 LM6000 PC
Volume I GE Industrial AeroDerivative Gas Turbines
Table of Contents (Continued)
Page
8-9.2 Wet Motoring (Liquid Fuel Only) ....................................................... 8-10
8-10 Starting and Operation........................................................................................ 8-10
8-10.1 Normal Starting Sequence ................................................................... 8-10
8-10.1.1 Hot Starts............................................................................. 8-11
8-10.2 Special Operating Requirements.......................................................... 8-11
8-10.2.1 Dual-Fuel Requirements ..................................................... 8-11
8-10.2.2 Fuel/Water Injection Requirements .................................... 8-15
8-10.2.3 High Pressure Steam Injection Requirements ..................... 8-15
8-10.2.4 SPRINT® Injection Requirements...................................... 8-16
8-10.2.5 Dual Gas System Requirements .......................................... 8-17
8-11 Shutdown............................................................................................................ 8-17
8-11.1 Normal Shutdown ................................................................................ 8-18
8-11.2 Emergency Shutdown .......................................................................... 8-18
8-11.3 Post-Shutdown Fire.............................................................................. 8-19
8-12 Restart................................................................................................................. 8-19
8-12.1 Hot Restarts.......................................................................................... 8-19
8-12.1.1 Restart Within 10 Minutes After Shutdown........................ 8-19
8-12.1.2 Restart More Than 10 Minutes After Shutdown................. 8-20
8-13 Windmilling........................................................................................................ 8-20
8-14 Engine Performance ........................................................................................... 8-21
8-14.1 Performance Measurement .................................................................. 8-21
8-14.2 Performance Data Recording ............................................................... 8-21
8-14.3 Component Life/Repair Intervals......................................................... 8-26
Chapter 9 Abnormal Operation ........................................................................................ 9-1
9-1 Purpose and Scope.............................................................................................. 9-1
9-2 General Definitions ............................................................................................ 9-1
9-3 Control Actions .................................................................................................. 9-1
9-3.1 Alarms .................................................................................................. 9-1
9-3.2 Power Cutback ..................................................................................... 9-1
9-3.2.1 Slow Decel to Minimum Load ............................................ 9-1
9-3.3 Shutdowns ............................................................................................ 9-2
9-3.3.1 Shutdown............................................................................. 9-2
9-3.3.2 Emergency Shutdown ......................................................... 9-2
9-3.3.3 Step-Decel to Idle/Shutdown .............................................. 9-2
9-3.3.4 Slow Decel to Minimum Load/Shutdown........................... 9-3
9-3.3.5 Aborted Start ....................................................................... 9-3
9-4 Operator Action .................................................................................................. 9-3
9-5 Hot Restarts ........................................................................................................ 9-4
9-6 Post-Shutdown Fire ............................................................................................ 9-4
9-7 Special Inspections ............................................................................................. 9-4
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GE Industrial AeroDerivative Gas Turbines Volume I
Table of Contents (Continued)
Page
Chapter 10 Troubleshooting ............................................................................................... 10-1
10-1 Purpose and Scope ............................................................................................. 10-1
10-2 Arrangement and Use......................................................................................... 10-1
10-2.1 Troubleshooting Reference Table ....................................................... 10-1
10-2.2 Numbered Troubleshooting Procedures .............................................. 10-1
10-2.3 Using This Chapter.............................................................................. 10-2
10-3 Troubleshooting Procedures .............................................................................. 10-2
10-3.1 Low Pressure Turbine Speed Sensor (XNSD) Testing........................ 10-2
10-3A Adjustment of Engine Balance Piston Pressure................................................. 10-3
10-4 Troubleshooting Reference Table...................................................................... 10-15
10-5 Troubleshooting Procedures .............................................................................. 10-36
TS-1: Hot Start............................................................................................... 10-36
TS-2: Post-Shutdown Fire ............................................................................. 10-37
TS-3: Inlet Screen Differential Pressure........................................................ 10-37
TS-4: Flameout .............................................................................................. 10-38
TS-5: Power Supply Failure .......................................................................... 10-38
TS-6: Fuel Supply Temperature .................................................................... 10-39
TS-7: Liquid Fuel Filter Differential Pressure............................................... 10-39
TS-8: Liquid Fuel/Water Manifold Temperature .......................................... 10-40
TS-9: Stall...................................................................................................... 10-40
TS-10: T3 (High Pressure Compressor Discharge Temperature).................... 10-42
TS-11: T48 (Low Pressure Turbine Inlet Temperature).................................. 10-42
TS-12: Lube Supply/Scavenge and VG Hydraulic Filter Differential
Pressure ............................................................................................ 10-43
TS-13: Chip Detector....................................................................................... 10-44
TS-14: Lube Scavenge Temperature ............................................................... 10-45
TS-15: Lube Scavenge Pressure ...................................................................... 10-46
TS-16: Lube Supply Temperature ................................................................... 10-46
TS-17: Lube Supply Pressure .......................................................................... 10-47
TS-18: Lube System - Miscellaneous.............................................................. 10-50
TS-19: XN2/LPC Speed and XNSD/LPT Speed - Not applicable to PC........ 10-51
TS-20: XN25/HPC Speed................................................................................ 10-52
TS-21: Overspeed ............................................................................................ 10-53
TS-22: Miscellaneous Liquid or Gas Fuel System Problems.......................... 10-54
TS-23: Variable-Geometry Systems (VBVs, VIGVs, and VSVs) .................. 10-55
TS-24: LVDTs and Torquemotors................................................................... 10-56
TS-25: Miscellaneous Starting Problems ........................................................ 10-57
TS-26: Engine Vibration.................................................................................. 10-62
TS-27: Temperature Sensors ........................................................................... 10-63
TS-28: Speed Sensors ...................................................................................... 10-64
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Table of Contents (Continued)
Page
TS-29: Flame Sensor........................................................................................ 10-64
TS-30: Thrust Balance Valve System .............................................................. 10-65
TS-30A: Thrust Balance Orifice System ............................................................ 10-66
TS-31: Miscellaneous Problems ...................................................................... 10-67
TS-32: Emissions ............................................................................................. 10-71
TS-33: Excessive Water Injection.................................................................... 10-72
Chapter 11 Maintenance Considerations ........................................................................... 11-1
11-1 Purpose and Scope.............................................................................................. 11-1
11-2 Levels of Maintenance ....................................................................................... 11-1
11-3 Standard Maintenance Practices......................................................................... 11-1
11-3.1 Points of Reference .............................................................................. 11-1
11-3.2 Maintenance Within an Enclosure ....................................................... 11-2
11-3.3 Electrical Bonding Straps..................................................................... 11-3
11-3.4 Torque .................................................................................................. 11-3
11-3.4.1 Tightening Procedures......................................................... 11-7
11-3.4.2 Running Torque................................................................... 11-9
11-3.4.3 Loose Fasteners ................................................................... 11-9
11-3.4.4 Standard Torque .................................................................. 11-9
11-3.5 Tri-Wing Fasteners .............................................................................. 11-11
11-3.5.1 Installation........................................................................... 11-11
11-3.5.2 Extraction ............................................................................ 11-11
11-3.6 Marking of Parts................................................................................... 11-12
11-3.7 Safety-Wiring....................................................................................... 11-13
11-3.7.1 Safety-Wiring General Practices ......................................... 11-13
11-3.7.2 Safety Wire Installation....................................................... 11-16
11-3.8 Safety Cable ......................................................................................... 11-17
11-3.8.1 Safety Cable General Practices ........................................... 11-17
11-3.8.2 Crimping Tool Verification................................................. 11-18
11-3.8.3 Safety Cable Installation ..................................................... 11-18
11-3.9 Correction of Leaks.............................................................................. 11-19
11-3.10 Unpacking and Repacking ................................................................... 11-21
11-3.11 Jackscrews............................................................................................ 11-21
11-3.12 Protective Closures and Caps............................................................... 11-22
11-3.13 Universal Fittings ................................................................................. 11-22
11-3.14 Cleanliness ........................................................................................... 11-23
11-3.15 Gaskets and Packing ............................................................................ 11-23
11-3.16 Tubes .................................................................................................... 11-23
11-3.17 Hoses .................................................................................................... 11-25
11-3.18 Clamps ................................................................................................. 11-26
11-3.19 Electrical Cables and Connectors ........................................................ 11-26
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Table of Contents (Continued)
Page
11-3.20 Bearing Handling................................................................................. 11-29
11-3.20.1 Preservation ........................................................................ 11-29
11-3.20.2 Heating and Chilling........................................................... 11-30
11-3.21 Spray Shields ....................................................................................... 11-31
11-3.22 Blending............................................................................................... 11-31
11-3.22.1 Blending General Practices................................................. 11-31
11-3.22.2 Hand Blending .................................................................... 11-31
11-3.22.3 Power Blending................................................................... 11-32
11-3.22.4 Component Specific Requirements .................................... 11-32
11-3.23 Swab Etching Procedure...................................................................... 11-36
11-3.24 Spot-Fluorescent-Penetrant Inspection................................................ 11-37
11-3.24.1 Spot-Fluorescent-Penetrant Inspection
Equipment/Materials............................................................ 11-37
11-3.24.2 Spot-Fluorescent-Penetrant Inspection Procedure.............. 11-38
11-3.25 Miscellaneous Procedures ................................................................... 11-39
11-3.26 V-Band (Coupling) Clamps................................................................. 11-41
11-3.26.1 Preinstallation Checks......................................................... 11-41
11-3.26.2 Installation .......................................................................... 11-43
Chapter 12 Preventive Maintenance .................................................................................. 12-1
12-1 Purpose and Scope ............................................................................................. 12-1
12-2 General Checks and Inspections ........................................................................ 12-1
12-2.1 Use of Inspection Tables and Instructions........................................... 12-1
12-2.1.1 Extent and Methods of Inspection ...................................... 12-1
12-2.1.2 Form of Inspection Tables .................................................. 12-1
12-3 Motoring............................................................................................................. 12-2
12-3.1 Dry Motoring....................................................................................... 12-2
12-3.2 Wet Motoring (Liquid Fuel Only) ....................................................... 12-3
12-4 Rigging and Idle Checks .................................................................................... 12-3
12-4.1 Rigging Checks.................................................................................... 12-3
12-4.2 Idle Checks .......................................................................................... 12-4
Chapter 13 Critical Parts Life Management - LM6000 PC Engine ................................ 13-1
13-1 Purpose and Scope ............................................................................................. 13-1
13-2 Definitions.......................................................................................................... 13-1
13-3 Affected Parts..................................................................................................... 13-3
13-4 Parameters to be Tracked................................................................................... 13-3
13-5 Calculating Accumulated Cycles and Recording Data ...................................... 13-4
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Table of Contents (Continued)
Page
Appendix A Fuel/Water Requirements................................................................................ A-1
Appendix A1 Fuel Gases for Combustion in AeroDerivative Gas Turbines............................ A-3
A1-1 General ................................................................................................. A-3
A1-2 Fuel Gas Classification ........................................................................ A-8
1-2.1 Natural Gas, Liquefied Natural Gas (LNG), Medium BTU
Natural Gas, and Liquefied Petroleum Gas (LPG).......... A-8
A1-2.1.1 Pipeline Natural Gas........................................... A-8
A1-2.1.2 Liquefied Natural Gas ........................................ A-9
A1-2.1.3 Medium BTU Natural Gas ................................. A-9
A1-2.1.4 Liquefied Petroleum Gases................................. A-9
A1-2.2 Gasification Fuels................................................................ A-9
A1-2.2.1 Oxygen Blown Gasification ............................... A-9
A1-2.2.2 Air Blown Gasification....................................... A-9
A1-2.3 Process Gases ...................................................................... A-10
A1-2.3.1 Blast Furnace Gases (BFGs) .............................. A-10
A1-2.3.2 Coke Oven Gases ............................................... A-10
A1-2.3.3 Flare Gases ......................................................... A-10
A1-3 Fuel Properties ..................................................................................... A-11
A1-3.1 Heating Value...................................................................... A-11
A1-3.2 Modified Wobbe Index Range ............................................ A-11
A1-3.3 Superheat Requirement ....................................................... A-12
A1-3.4 Gas Constituent Limits........................................................ A-12
A1-3.5 Gas Fuel Supply Pressure.................................................... A-12
A1-4 Contaminants ....................................................................................... A-12
A1-4.1 Particulates .......................................................................... A-13
A1-4.2 Liquids................................................................................. A-13
A1-4.3 Sulfur ................................................................................... A-13
A1-4.3.1 Hot Gas Path Corrosion...................................... A-13
A1-4.3.2 HRSG Corrosion ................................................ A-14
A1-4.3.3 Selective Catalytic Reduction (SCR) Deposition A-14
A1-4.3.4 Exhaust Emissions.............................................. A-15
A1-4.3.5 Elemental Sulfur Deposition .............................. A-15
A1-4.4 Siloxanes ............................................................................. A-15
A1-5 Definitions ............................................................................................ A-16
A1-5.1 Dew Point............................................................................ A-16
A1-5.2 Dry Saturated Condition...................................................... A-16
A1-5.3 Gas Hydrates ....................................................................... A-16
A1-5.4 Gas Hydrate Formation Line............................................... A-16
A1-5.5 Glycol .................................................................................. A-16
A1-5.6 Odorant................................................................................ A-16
A1-5.7 Superheat............................................................................. A-16
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Page
A1-5.8 Saturation Line.................................................................... A-16
A1-5.9 Wet Saturated Condition..................................................... A-16
Appendix A2 Liquid Fuel Requirements for GE AeroDerivative Gas Turbines ..................... A-17
A2-1 Fuel Specifications .............................................................................. A-17
A2-2 Property Requirements ........................................................................ A-18
A2-2.1 Composition........................................................................ A-18
A2-2.2 Viscosity ............................................................................. A-18
A2-2.3 Wax..................................................................................... A-19
A2-2.4 Additives............................................................................. A-19
A2-3 Additional Requirements..................................................................... A-19
A2-3.1 Fuel Temperature Requirements......................................... A-19
A2-3.2 Filtration.............................................................................. A-19
A2-4 Fuel Handling ...................................................................................... A-19
A2-4.1 Additional Requirements for Bio-Diesel Fuel .................... A-20
A2-5 Fuel Sampling...................................................................................... A-21
Appendix A3 Requirements for Water and Steam Purity for Injection in AeroDerivative
Gas Turbines ................................................................................................ A-25
A3-1 Applicable Documents ........................................................................ A-25
A3-2 Water Sampling Requirements ............................................................ A-26
A3-3 Water Purity Requirements ................................................................. A-26
A3-4 Sodium & Potassium Limits in Water or Steam.................................. A-26
A3-5 Water Filtration Requirements ............................................................ A-27
A3-6 Steam Requirements ............................................................................ A-27
A3-7 Steam Purity ........................................................................................ A-27
A3-8 Steam Sampling................................................................................... A-27
Appendix A4 Compressor Cleaning Water Purity Specification for GE Aircraft Derivative Gas
Turbines in Industrial Applications............................................................... A-29
A4-1 Applicable Documents ........................................................................ A-29
A4-1.1 Environmental Protection Agency (EPA) Test Methods.... A-29
A4-2 Sampling Requirements....................................................................... A-30
A4-3 Chemical Requirements....................................................................... A-30
A4-4 Filtration Requirements ....................................................................... A-30
Appendix A5 Liquid Detergent for Compressor Cleaning for GE Aircraft Derivative
Gas Turbines ............................................................................................... A-31
A5-1 Applicable Documents ........................................................................ A-31
A5-2 Detergent Properties ............................................................................ A-31
A5-2.1 Composition........................................................................ A-31
A5-2.2 Biodegradability.................................................................. A-31
A5-2.3 Toxicity............................................................................... A-31
A5-2.4 Health and Safety Information............................................ A-32
A5-2.5 Solids .................................................................................. A-32
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Page
A5-2.6 Physical and Chemical Properties ....................................... A-32
A5-3 Test Requirements................................................................................ A-32
A5-3.1 Liquid Detergent ................................................................. A-32
A5-3.1.1 Residue or Ash Content...................................... A-32
A5-3.1.2 Low-Temperature Stability ................................ A-32
A5-3.1.3 Cold Weather Solution Compatibility ................ A-32
A5-3.1.4 Hard Water Compatibility .................................. A-32
A5-3.1.5 Acid and Alkali Acceptance............................... A-32
A5-3.1.6 Salt Water Tolerance .......................................... A-32
A5-3.1.7 Viscosity ............................................................. A-32
A5-3.1.8 pH ....................................................................... A-32
A5-3.2 Cleaning Solution................................................................ A-33
A5-3.2.1 Corrosive Elements ............................................ A-33
A5-3.2.2 pH ....................................................................... A-33
A5-4 Test Methods........................................................................................ A-33
A5-4.1 Residue or Ash Content....................................................... A-33
A5-4.2 Hard Water Compatibility................................................... A-33
A5-4.2.1 Preparation of Synthetic Hard Water ................. A-33
A5-4.2.2 Hard Water Test ................................................. A-33
A5-4.3 Acid and Alkali Acceptance................................................ A-33
A5-4.4 Salt Water Tolerance ........................................................... A-34
A5-4.5 Elemental Content ............................................................... A-34
A5-5 Compatibility ....................................................................................... A-34
A5-5.1 Engine Materials ................................................................. A-34
A5-5.2 Titanium Stress Corrosion................................................... A-34
A5-6 Cold Weather Usage ............................................................................ A-34
Appendix A6 Lubricating Oil Guidance for GE Aero Engines ................................................ A-35
A6-1 Oil Specifications ................................................................................. A-35
A6-2 Applicable Documents ......................................................................... A-35
A6-2.1 Oil Specifications ................................................................ A-35
A6-3 Recommendations ................................................................................ A-35
A6-3.1 Oil Mixing ........................................................................... A-35
A6-3.2 Material Compatibility ........................................................ A-35
A6-4 Fitness Criteria ..................................................................................... A-36
A6-5 References ............................................................................................ A-36
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LM6000 PC ORIGINAL INSTRUCTIONS GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume I
5 CHAPTER 1
Introduction
1-1 Purpose and Scope of Volume II contains the individual work pack-
Technical Manual ages for on-site maintenance, including engine
changeout. Volume II also contains the recom-
Volumes I and II of this manual contain mended tooling and consumables provisioning
information to be used for the on-site for on-site maintenance, as well as, storage
installation, operation, and maintenance of and shipment preparation procedures.
the GE LM6000 Series Gas Turbine.
Level 1 maintenance covers all work on the
1-2 Arrangement and Use of exterior of an installed gas turbine, including
Technical Manual scheduled inspections, compressor cleaning
(water-wash), and engine changeout. Level 2
This manual consists of two volumes, each modular maintenance covers removal and
arranged to provide easy access to all required reinstallation of one or more major sections of
information. Volume I provides general the engine, including, but not limited to, the
descriptions of the engine and associated sys- low pressure turbine (LPT) and high pressure
tems, as well as, operating and troubleshoot- turbine (HPT) modules, the combustor, the
ing information. low pressure compressor (LPC) module, and
the variable inlet guide vane (VIGV) module.
The chapters in Volume I are numbered with
Arabic numerals. Figures, tables, and pages Each work package in Volume II (or subordi-
are each numbered sequentially, starting with nate work package, as required) is numbered
the number one (1), preceded by the chapter and arranged in the following general
number and a dash, for each chapter; e.g., fig- sequence:
ure 1-1. Paragraphs are identified and layered 1. Introduction
in the following manner: 2. Reference Material
3. Support Equipment
1-1 Main Topic/Paragraph 4. Consumable Material
1-1.1 First-level subordinate paragraph 5. Expendable Material
1-1.1.1 Second-level subordinate paragraph 6. Component Removal
1-1.1.1.1 Third-level subordinate paragraph 7. Component Installation
1-1.1.1.1.1 Fourth-level subordinate paragraph
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1-3 Notes, Cautions, and dispose of superseded pages. Page changes are
Warnings designated by the change number of the effec-
tive change at the bottom of each affected
Notes, Cautions, and Warnings will be found page. Refer to the list of effective pages for
throughout this publication. It is important that current change page applicability.
the significance of each is thoroughly under-
stood by personnel using this technical man- Illustrations (line art and photographs) repre-
ual. Their definitions are as follows: sent the equipment configuration at time of
inclusion in this technical manual. They will
WARNING Warnings refer to procedures
not necessarily be changed to represent all
or practices that may result in injury or
death if not followed correctly. and/or the latest equipment or configuration.
They are to be used only as an aid to supple-
CAUTION Cautions refer to procedures or ment the text and the parts list.
practices that may damage or destroy equip-
ment if not followed correctly. Changes or additions deemed necessary for
proper operation, maintenance, and safety
NOTE Notes highlight an essential proce-
improvements should be submitted to:
dure or a condition that requires emphasis.
1-4 Changes to Technical GE Aircraft Engines
Manual Marine & Industrial Customer Service
Mail Drop S-155,
A manual change is defined as the reissue of 1 Neumann Way
selected pages of the manual. A revision is Cincinnati, Ohio
defined as the reissue of the entire manual. 45215-6301 USA
Attention: Documentation Programs
Changes are indicated by a vertical bar | in the
margin, alongside the text change. Changes to The sample form shown in may be repro-
illustrations, diagrams, and schematics are duced and used for this purpose.
indicated in the same manner. Since previous 1-1
change symbols are deleted when a page is 1-5 Measurement Units
subsequently changed, the symbols show the
latest changes only. The Système International d'Unités (SI) or
metric system is being adopted throughout the
Manual changes and revisions are mailed to world. For this reason, SI unit conversion
all authorized LM6000 manual holders at the tables are shown in tables 1-1 and 1-2. Frac-
time the issues are published. When changes tions and decimal equivalents are shown in
are received, insert the latest change pages and table 1-3.
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Figure 1-1Publication Change Request
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Table 1-1Metric and SI Unit Conversion Factors
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Table 1-2Temperature Conversion Chart
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Table 1-3Conversion Table - Fractions to Decimals
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The introduction of torque wrenches cali- This section describes general safety precau-
brated in newton-meters has been commensu- tions that are not related to specific procedures
rate with the adoption of the SI system. These and therefore do not appear elsewhere in this
will eventually replace torque wrenches cali- manual. The precautions should be clearly
brated in kilogram-meters (kgm). Although understood and applied wherever appropriate
the following values are not mathematically in all phases of installation, operation, and
precise (3.5 kgm equals 34.2 N·m), they are maintenance.
considered adequate. To convert kilogram-
meters (kgm) to newton-meters, (N·m) move 1-7.1 Health Hazards
the decimal point one place to the right. For
example, 3.5 kgm would become 35 N·m. To WARNING Use all cleaning solvents, fuels,
convert kilogram-centimeters (kg cm) to new- oils, adhesives, epoxies, and catalysts in a
ton-meters, move the decimal point one place well-ventilated area. Avoid frequent and
to the left. For example, 50 kg cm would prolonged inhalation of fumes. Concentra-
become 5.0 N·m. tions of fumes of many cleaners, adhesives,
and esters are toxic and will cause serious
The SI units shown in this manual are direct adverse health effects and possible death if
mathematical conversions and may be inhaled frequently. Avoid frequent or pro-
rounded off, in most instances, at the user's longed exposure to the skin. Wear protec-
discretion. Examples of units that may be tive gloves and wash thoroughly with soap
rounded off are those used for temperatures, and warm water as soon as possible after
torque values, pressures, etc. Examples of SI exposure to such materials. Take special
units that may not be rounded off are those precautions to prevent materials from
used for drop checks, rigging adjustments, entering the eyes. If exposed, rinse the eyes
runouts, etc. in an eye bath fountain immediately and
report to a physician. Avoid spilling freon
1-6 Glossary of Terms or similar solvents on the skin. Extremely
rapid evaporation of these solvents has a
Table 1-4 lists and defines the abbreviations refrigerating effect and may cause serious
most commonly used in this manual. frostbite. Do not allow adhesive to contact
the skin. Rapid bonding of certain adhe-
1-7 Safety Precautions sives will cause instant adhesion to body
members or objects. Do not attempt to
This technical manual is designed to provide forcefully separate body members if
safe procedures and processes for accomplish- bonded together. Consult the area supervi-
ing the installation, operation, and mainte- sor or a physician for procedures for sepa-
nance tasks required for the LM6000 It is ration. Carefully review the hazard
therefore very important that all Warnings and information on the appropriate material
Cautions be clearly understood and observed safety data sheet and follow all applicable
by users of this manual. personal protection requirements.
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Table 1-4Abbreviations
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Table 1-4Abbreviations (Continued)
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1-7.2 Fire Hazards 1-7.4 Heated/Chilled Part Hazards
WARNING Keep all cleaning solvents, WARNING Use thermally insulated gloves
fuels, oils, esters, and adhesives away from when handling heated or chilled parts to
open flame space heaters, exposed-element prevent burning or freezing hands. Parts
electric heaters, sparks, or flame. Do not chilled to supercold temperatures (-40°F to
smoke when using flammables, in the vicin- -65°F [-40°C to -53°C]) can cause instant
ity of flammables, or in areas where flam- freezing of hands if handled without protec-
mables are stored. Provide adequate tive gloves.
ventilation to disperse concentrations of
potentially explosive fumes or vapors. Pro- 1-7.5 Electrical Hazards
vide approved containers for bulk storage
of flammable materials and approved dis- WARNING Use extreme care when work-
pensers in the working areas. Keep all con- ing with electricity. Electricity can cause
tainers tightly closed when not in use. shock, burns, or death. Electrical power
shall be off before connecting or disconnect-
1-7.3 Compressed Air Hazards ing electrical connectors. Lethal output
voltages are generated by the ignition
WARNING Air pressure used in work exciter. Do not energize the exciter unless
areas for cleaning or drying operations the output connection is properly isolated.
should be regulated to 29 psi (200 kPa) or Be sure all leads are connected and the plug
less. Use approved safety equipment (gog- is installed or all personnel are cleared to at
gles/face shield) to prevent injury to the least 5 feet (2 m) before firing the exciter. If
eyes. Do not direct the jet of compressed air the exciter is removed, fire it only in the iso-
at yourself or other personnel, or so that lation chamber of the tester.
refuse is blown onto adjacent work stations.
If additional air pressure is required to dis- WARNING When using equipment pro-
lodge foreign materials from parts, ensure vided with, or associated with, high-fre-
that approved safety equipment is worn quency power generators, be sure that all
and move to an isolated area. Be sure that components are adequately isolated to pre-
the increased air pressure is not detrimen- vent serious injury to the operator. Be sure
tal or damaging to the parts before apply- the generator power is off when connecting
ing high-pressure jets of air. or positioning connectors and cables and
when adjusting heater elements.
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1-7.6 Paints and Finishes Hazards WARNING When a torque multiplier is to
be used, it must have adequate capacity to
WARNING Apply paints, finishes, and pre- meet the specified torque requirement of
servatives in approved spray booths or iso- the operation. The torque multiplier manu-
lated areas equipped with air cleaning and facturer's instructions and the instructions
spray-evacuation equipment. Ensure that contained herein must be followed exactly
all lighting and electrical gear is of the in order to guard against the possibly haz-
explosion-proof type. Wear appropriate ardous results of tool misuse.
breathing filters, eye protection, and such
clothing as is required to protect the skin. 1-7.9 Gas Turbine Operational
Consult the material safety data sheet for Hazards
specific personal protection requirements.
The outside surfaces of the engine are not
1-7.7 Procedural Hazards insulated. Adequate precautions should be
taken to prevent operating personnel from
WARNING Observe all specified and logi- inadvertently coming in contact with these hot
cal safety practices when assembling or dis- surfaces.
assembling the gas turbine. Wear safety
glasses or other appropriate eye protection The LM6000 Gas Turbine is a source of con-
at all times. Do not allow safety wire or wire siderable noise. It is necessary for personnel
clippings to fly from the cutter when working on the gas turbine or in its vicinity to
removing or installing wire. Do not use fin- wear proper ear protection equipment when it
gers as guides when installing parts or to is operating.
check alignment of holes. Use only correct
tools and fixtures and always use only as Operating machinery rotates at high speeds. In
recommended. Avoid short cuts such as the remote case of major parts failure, the cas-
using fewer than recommended attaching ing may not contain all of the fragments. It is
bolts or using shorter, or inferior-grade prudent to locate fuel and potentially hazard-
bolts. Heed all warnings in the manual text ous lines or equipment, such as control or
to avoid injury to personnel or damage to shutoff valves, so that they are not in the plane
gas turbine parts. of the high speed rotating parts. If it is neces-
sary to locate such items in this zone, they
1-7.8 Tooling Hazards should be suitably protected. People should
not be located in the plane of the rotating
WARNING Improperly maintained tools parts.
and support equipment can be dangerous
to personnel and can damage gas turbine Rotating parts of the starter operate at a very
parts. Observe recommended inspections high speed. Personnel should not be stationed
and schedules for inspections to avoid in the plane of the starter during start cycle.
unanticipated failures. Use tooling only for
the purpose for which it was designed and Low-pressure, high-velocity airflow created
avoid abuse. Be constantly alert for dam- by the compressor can draw objects and/or
aged equipment and initiate appropriate personnel into the engine. Although use of an
action for approved repair immediately. inlet screen or other protective measure is
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required, personnel should not stand in front compressor at crank speed and the poorly
of the inlet while the engine is operating. atomized water entering the rotor cooling cir-
cuit can cause accumulation of water in the
Suitable fire protection equipment should be compressor bore. This may result in unbalance
provided for the installation. Carbon dioxide, and subsequent damage to the turbine.
halides, fog, water, or chemical fire extin-
guishing systems may be used. In the event Do not override any engine control permis-
that the fire protection system is discharged sives. Overriding permissives can cause
while personnel are inside the enclosure, all engine operational problems, damage to the
personnel should immediately exit the enclo- engine, and, in certain cases, injury to
sure to prevent ingestion of the extinguishing personnel.
medium. Discharge of fine chemical or water WARNING When the gas turbine is oper-
mists directly on gas generator casings is per- ating, do not remain in the vicinity of the
missible. The use of chemical fire extinguish- package doors. Do not look through any
ing media will require the disassembly of the glass windows associated with package
engine for cleaning. walls or doors.
Suitable explosive mixture sensing devices
WARNING When entering the gas turbine
should be provided to sense any leakage of
enclosure, the following requirements shall
fuel (both into the packager's enclosure and
be met:
into the fuel manifold). These devices should
also shut down the gas turbine if leakage is • The gas turbine shall be shut down.
present. If this occurs, determine and correct
the cause of the leakage before continuing • Module entry during engine operation
operation. The enclosure and surrounding area is prohibited in general. If entry should
should also be properly ventilated to clear any be required during engine operation,
explosive fumes prior to restarting. contact GE Field Service for a represen-
tative who is trained to enter the module
The engine is provided with various sensors under such conditions.
and monitoring systems that are necessary for
proper operation, engine health, and safety. • The fire extinguishing system shall be
Bypassing, disabling in any way, or running made inactive according to the cus-
with sensors/monitoring systems inoperative tomer's procedures.
can result in engine damage. This includes the
bypassing of any individual sensor when more • Secondary air to the enclosure shall be
than one sensor is provided for a given shut off, since high secondary airflow
parameter. For example, bypassing one T4.8 may prevent opening or closing the
sensor could result in damage to the HPT enclosure door.
system. • The enclosure door should be kept open.
Do not bypass any of the protective control If the gas turbine is operating, an
features found in the SPRINT® system. Spe- observer should be stationed at the
cifically, do not turn on the SPRINT® water enclosure door and confined space entry
spray to rinse the compressor during a crank procedures shall be followed.
soak. The system is not designed to rinse the
1-12
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• Allow gas turbine to cool down. Avoid 1-8 Special Inspections
contact with hot parts, and wear ther-
mally insulated gloves as necessary. The maintenance of the gas turbine requires
that inspection checks be made periodically.
• Ear protection shall be worn if gas tur-
The inspection requirements and limits
bine is operating. throughout this manual are based on operation
• Do not remain in the enclosure or in the within specified limits. In addition to the regu-
plane of rotation of the starter when lar inspections, there are those necessary when
starting or motoring the gas turbine. the gas turbine has been operated outside of
the specified limits, for example, off-schedule
• When performing maintenance on elec- variable geometry operation, overspeed, or
trical components, avoid shocks and overtemperature. There are also special
burns by turning off electrical power to inspections necessary for gas turbines exposed
those components, except when power is to abnormal conditions. These may include,
required to take voltage measurements. for example, failures with significant damage
and other abnormal exposure such as an instal-
• Lock out all controls and switches, if lation fire or mishap during transportation,
possible; otherwise, tag electrical handling, or storage. This manual includes
switches out of service to prevent inad- routine inspection requirements to be accom-
vertent activation. Tag the engine oper- plished for preventive maintenance and for
ating controls do not operate to prevent troubleshooting. It also includes criteria for
starting during a desired shutdown con- determining if special inspections are neces-
dition. sary because of exposure to abnormal
conditions.
1-7.10 Environmental Hazards
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 prod-
uct information, and applicable local, state,
and federal disposal requirements for
proper waste management practices.
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3 CHAPTER 2
Gas Turbine General Description and Model Summary
2-1 Purpose and Scope HPT. The HPC and HPT drive the HPC and
LPC through concentric drive shafts.
This chapter provides a general description of
the LM6000 PC Gas Turbine and its design Air enters the gas turbine at the VIGVs or inlet
features. It also summarizes the various model frame and passes into the LPC. The LPC com-
configurations available. Standard and presses the air by a ratio of approximately
optional equipment lists are also provided. 2.4:1. Air leaving the LPC is directed into the
HPC. Variable bypass valves (VBV) are
2-2 General Description and arranged in the flow passage between the two
Features compressors to regulate the airflow entering
the HPC at idle and at low power. To further
2-2.1 General Description control the airflow, the HPC is equipped with
variable stator vanes (VSVs). The HPC com-
The LM6000 PC Gas Turbine (figure 2-1) is a presses the air to a ratio of approximately
two shaft machine capable of driving a load 12:1, resulting in a total compression ratio of
from either the front or rear of the low pres- 30:1, relative to ambient. From the HPC, the
sure rotor (LPR). air is directed into the single annular combus-
tor section, where it mixes with the fuel from
The dual-rotor gas turbine consists of a vari- the 30 fuel nozzles. The fuel/air mixture is ini-
able inlet guide vane (VIGV) or inlet frame tially ignited by an igniter and, once combus-
assembly, a 5-stage low pressure compressor tion is self-sustaining, the igniter is turned off.
(LPC), a 14-stage variable-geometry high The hot gas that results from combustion is
pressure compressor (HPC), a single annular directed into the HPT which drives the HPC.
combustor (SAC), a 2-stage high pressure tur- This gas further expands through the LPT,
bine (HPT), a 5-stage low pressure turbine which drives the LPC and the output load.
(LPT), a transfer gearbox assembly (TGB),
2-1
and accessories. 2-2.2 Model Summary
The LPR consists of the LPC and the LPT that The information in this manual covers
drive it. Attachment flanges are available on LM6000 PC Gas Turbine models listed in
both the front and/or rear of the LPR for table 2-1. Model designations are associated
connection to the packager-supplied power with the variety of fuel systems available for
shaft and load. The high pressure rotor use on the LM6000 PC for either gas or liquid
consists of the 14-stage HPC and the 2-stage fuel and for water or steam NOx suppression.
HPT that drive it. The high pressure core Additional model designations will be
consists of the HPC, the combustor, and the assigned based on configuration requirements
for further applications.
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Figure 2-1 LM6000 PC Gas Turbine Cross Section (Sheet 1 of 2)
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Figure 2-1 LM6000 PC Gas Turbine Cross Section (Sheet 2 of 2)
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Table 2-1 LM6000 PC Model Summary
Model Designation Description
7LM6000-PC-NG Gas fuel without NOx suppression; equipped with gas fuel manifold and 30 gas fuel
nozzles.
7LM6000-PC-NGW Gas fuel with water injection for NOx suppression; equipped with a gas manifold, a
water manifold, and 30 gas fuel nozzles configured for water injection.
Also available:
Medium BTU (450-650 BTU per standard cubic foot [SCF]) gaseous fuel without
NOx suppression, equipped with gas manifolds for natural gas (for starting and low
power) and medium BTU fuel for high power operation.
Contact GE for further information
7LM6000-PC-NGS Gas fuel with steam injection for NOx suppression; equipped with a gas manifold, a
steam manifold, and 30 gas fuel nozzles configured for steam injection.
7LM6000-PC-NLW Liquid fuel with water injection for NOx suppression; equipped with a primary liquid
fuel manifold, a secondary liquid fuel/water manifold, 30 fuel nozzles, and an off-
gas-turbine-mounted pressurizing valve system. The secondary fuel manifold piping
includes a mixing tee for introducing water into the fuel system.
7LM6000-PC-NDW Liquid gas fuel with injection for NOx suppression; equipped with a gas fuel
manifold, a primary liquid fuel manifold, a secondary liquid fuel/water manifold, 30
dual-fuel nozzles, and an off-gas-turbine-mounted pressurizing valve system. The
secondary fuel manifold piping includes a mixing tee for introducing water into the
fuel system.
7LM6000-PC-NL Liquid fuel without NOx suppression; equipped with a primary liquid fuel manifold, a
secondary liquid fuel/water manifold, 30 fuel nozzles, and an off-gas-turbine-
mounted pressurizing valve system.
7LM6000-PC-ND Liquid gas fuel without injection for NOx suppression; equipped with a gas fuel
manifold, a primary liquid fuel manifold, a secondary liquid fuel/water manifold, 30
dual-fuel nozzles, and an off-gas-turbine-mounted pressurizing valve system.
2-2.3 Summary of Changes from the The LPT has additional exhaust expansion and
PA Model power extraction due to modifications to the
casing, stages 3-5 blades, stages 4 and 5 disks
The LM6000 PC Gas Turbine (derived from and vanes, and rear frame. The aft drive shaft
the LM6000 PA) incorporates design changes has an optional coupling flange for rear drive
to the LPC, HPC, LPT, balance piston system, units. The casing is cooled by a cooling mani-
and fuel systems. fold using LPC discharge air. Structurally, the
LPT is larger in diameter, slightly longer, and
The LPC employs redesigned stator vanes. has 14 struts versus 10. Exit flanges for both
inner and outer flowpaths have been modified,
The HPC casing has been redesigned to which requires a unique exhaust 2:1 area ratio
accommodate stage 8 bleed for LPT cooling. diffuser.
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The thrust balance piston control system has a • Accessory gearbox-driven lube oil supply
thrust balance control valve located off-gas and scavenge pumps and gas turbine-
turbine. The compressor bleed air from the mounted interconnecting piping
11th stage compressor bleed manifold must be
directed to the base mounted valve and the • Forward side-mount trunnions
valve discharge piped back to the balance pis-
ton manifold on the turbine rear frame. • Aft-mount clevises
2-2.4 Standard and Optional • Variable-geometry (VG) control systems
Equipment for the VIGV, VBV, and VSV systems
The LM6000 PC Gas Turbine comes fully Certain items of optional equipment, not listed
assembled with the following standard equip- above, are provided as packager-installed kits.
ment installed and tested at the factory: The specific configuration of the LM6000 and
installation will determine which of these kits
• Single-stage VIGV system or inlet frame are installed. For additional information, refer
to the packager's manual.
• Five-stage LPC
2-2.5 Standard and Optional
• LPC discharge bypass air collector and Instrumentation
actuators
The LM6000 PC gas turbine is equipped with
• 14-stage HPC the sensors standard shown in table 2-2.
Optional sensors are listed in table 2-3. Pres-
• Annular combustor sure taps are provided at the following loca-
tions for packager-supplied sensors:
• Fuel system (fuel nozzles, connectors,
manifolds, and off-gas turbine pressuriz- • Lube oil supply line
ing valve, as applicable)
• Lube oil scavenge return line
• High pressure steam/water injection mani-
folds as applicable for NOx suppression • HPC discharge static pressure (PS3)
• Ignition system (igniter and exciter) • Liquid fuel manifolds (as applicable)
• Two-stage HPT • LPC inlet (P2)
• Five-stage LPT • HPC inlet (P25)
• Output shaft coupling adapter • HPC inlet static pressure (PS25 - front
frame)
• Accessory gearbox assembly, transverse
gearbox, and accessories • LPT inlet total pressure (P48)
• Thrust balance cavity pressure (PTB)
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Table 2-2 Standard Instrumentation
Qty/Engine Parameter/Sensor Description
2 HP rotor speed (XN25) sensors - magnetic pickup type - located on AGB.
2 LPT rotor (XNSD) speed sensors - magnetic pickup type - located in the turbine rear
frame.
8 LPT inlet temperature (T48) sensors - KP/KN thermocouples - located on LPT stator
case.
2 Accelerometers - located on the compressor rear frame and turbine rear frame
(redundant accelerometers optional).
7 Resistance temperature detectors (RTDs) - dual-element lube oil supply and scavenge -
located in on-gas turbine lube line (redundant dual-element RTDs optional).
3 Chip detectors - remote-indicating type - located in AGB-sump, B-sump, and common
lube oil scavenge lines (C-, D-, and E-sump chip detectors optional).
1 LPT inlet pressure (P48) probe - total pressure - located on the LPT casing.
1 LPC inlet temperature and total pressure (T2/P2) probe - dual element RTD and P2
sensing port - located on the VIGV case or inlet frame (redundant probe optional).
1 HPC inlet temperature and total pressure (T25/P25) probe - dual-element RTD and P25
sensing port - located on front frame (redundant probe optional).
2 VSV position sensors - linear variable differential transformer (LVDT) - located in both
VSV actuators.
2 VBV position sensors - LVDT - located in two of the actuators.
2 VIGV position sensors - LVDT - located in both VIGV actuators (VIGV assemblies only).
1 HPC discharge temperature (T3) sensor - dual-element KP/KN thermocouple mounted
on the compressor rear frame.
Table 2-3 Optional Instrumentation
Qty/Engine Parameter/Sensor Description
2 Accelerometers - located on the compressor rear frame (CRF) and LPT rear frame.
7 Sensors for lube oil scavenge and supply temperatures - dual element RTD 0 located
in on-gas turbine lube oil lines.
3 Chip detectors - remote-indicating type - located in on-gas turbine C-sump, D-sump,
and E-sump.
1 Probe for LPC inlet temperature and total pressure probe (T2/P2) - located on the
VIGV case.
1 Probe for HPC inlet temperature and total pressure probe (T25/P25) RTD - located on
front frame.
2 Ultraviolet combustor flame sensors (packager must supply).
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2 CHAPTER 3
Gas Turbine Package
3-1 Purpose and Scope Typical package components include:
This chapter provides a brief general descrip- • Gas turbine base
tion of the LM6000 gas turbine package and
its packager-supplied major components. • Mounting structure
Since individual packages will vary according
• Sound enclosure
to customer installation requirements, detailed
information is not provided in this chapter. For • Inlet and exhaust systems
more specific information, contact the pack-
ager. Additional information is provided in • Controls and electrical systems
other chapters of this manual and in the pack-
ager's manual. • Drains and vents
3-2 Package Description • Fuel, lube, and hydraulic systems
The gas turbine package comprises a complete • Instrumentation and condition-monitoring
electrical generating or mechanical drive sys- systems
tem built around the LM6000 gas turbine. The
package provides the structure, interfaces, ser- • Cooling systems
vice connections, and controls necessary to
operate the LM6000 and to utilize its energy • Front and/or rear drive interfaces
and/or shaft output. This package needs only
• Noise and emission suppression systems
to be installed or erected at the customer's site
and connected to the appropriate interfaces • Interconnecting wiring and piping
and services (fuel, electric, etc.).
• Fire and safety systems
• Anti-icing and water-wash systems
• Compressor bleed air discharge
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0 CHAPTER 4
Gas Turbine Assembly Description
4-1 Purpose and Scope • High pressure turbine (HPT)
This chapter describes the LM6000 PC Gas • Low pressure turbine (LPT)
Turbine assembly, equipment, and systems.
• Turbine rear frame (TRF) assembly
4-2 General Description
• Accessory gearbox (AGB) assembly and
4-2.1 Main Components accessories
The LM6000 PC gas turbine is a dual-rotor, The high pressure rotor (HPR) system is com-
concentric drive shaft gas turbine, capable of prised of a 14-stage HPC, a single annular
driving a load from the front and/or rear of the combustor (SAC), and a 2-stage HPT. The
low pressure rotor (LPR). Figure 4-1 is a cross HPC and the HPT are connected by mating
section of the engine, showing the significant splines. The HPR turns clockwise when
design features of the LM6000 PC gas turbine. viewed from aft, looking forward. The high
Figure 4-2 identifies the principal LM6000 PC pressure stator system consists of the HPC and
gas turbine components, as listed below: turbine stators.
• Variable inlet guide vane (VIGV) assem- The LP system is comprised of a five-stage
bly (the power generation application can LPC and a five-stage LPT, both connected to a
be provided with or without VIGV concentric drive shaft. The LP rotor turns
assembly) clockwise when viewed from aft, looking for-
ward. The LP stator system consists of the
• Five-stage low pressure compressor (LPC) LPC and turbine stators. Drive adapters are
provided on both the front and rear of the LP
• Front frame assembly rotor for connection to the customer-supplied
power shaft and load.
• Bypass air collector
Three structural frames provide bearing sup-
• 14-stage variable-geometry (VG) high port for the two rotors used in the LM6000 PC
pressure compressor (HPC) gas turbine. These include the front frame, the
CRF, and the TRF. This configuration pro-
• Compressor rear frame (CRF) assembly vides excellent dynamic and mechanical sta-
bility and allows more precisely controlled
• Single annular combustor (SAC) assembly compressor and turbine blade and vane tip
clearances.
4-1
4-2
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Figure 4-1 LM6000 PC Gas Turbine Airflow Cross Section (Sheet 1 of 2)
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Figure 4-1 LM6000 PC Gas Turbine Airflow Cross Section (Sheet 2 of 2)
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Figure 4-2 LM6000 PC Gas Turbine Major Components (Sheet 1 of 3)
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Figure 4-2 LM6000 PC Gas Turbine Major Components (Sheet 2 of 3)
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Figure 4-2 LM6000 PC Gas Turbine Major Components (Sheet 3 of 3)
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4-2.2 Engine Airflow trailing flaps. The variable flaps can be rotated
from -10 degrees open to +60 degrees closed
Air enters the engine at the inlet of the VIGV by means of an actuator ring (unison ring)
and passes into the LPC. Engine airflow is driven by twin hydraulic actuators at the 3:00
shown in figure 4-1. The LPC compresses the and 9:00 o'clock positions. Both actuators are
air by a ratio of approximately 2.4:1. Air leav- equipped with linear variable differential
ing the LPC is directed into the HPC and is transformers (LVDTs).
regulated at idle and low power by variable
bypass valves (VBV) arranged in the flow Normal engine operation range is approxi-
passage between the two compressors. mately -5 degrees open (full power) to +35
degrees closed (idle). The flaps will also close
The airflow in the 14-stage HPC is regulated during large power reductions to reduce the
by VIGV and five stages of variable stator LPC flow rate quickly in order to maintain the
vanes (VSV). The HPC compression ratio is LPC stall margin. The VIGV system improves
approximately 12:1. HPC discharge and stage performance for both simple cycle and heat
8 bleed air are extracted, as necessary, for recovery cycles. It also helps minimize VBV
emissions control. Compressor discharge air is bypass flow and pressure levels, thereby
then directed to the combustor section. reducing associated flow noise. A pressurized
rotating seal between the VIGV hub and the
Air entering the combustor is mixed with the LPC rotor prevents ingestion of unfiltered air
fuel provided by 30 fuel nozzles. The fuel/air into the flowpath.
mixture is ignited by an igniter that is deacti-
vated once combustion becomes self-sustain- The air intake section is designed to interface
ing. Combustion gases then exit to the HPT. with a radial inlet duct (which allows inlet air
to be drawn from the side or top, rather than
Hot gases from the combustor are directed from the front) or an axial inlet system. The
into the HPT, which drives the HPC. The radial inlet duct is compatible with either for-
exhaust gases exit the HPT and enter the LPT, ward or rear drive installations; the axial inlet
which drives both the LPC and the output can be used only in rear drive installations.
load. The exhaust gases pass through the LPT
and enter the exhaust duct. The LM6000 PC models without a VIGV
have a 43 strut inlet frame. LM6000 PC can be
4-3 Variable Inlet Guide Vanes provided with or without the VIGV assembly.
The air intake section of the engine consists of 4-4 Low Pressure Compressor
an axial flow section containing a VIGV sys-
tem. The VIGV assembly is located at the 4-4.1 General Description
front of the LPC and allows flow modulation
at partial power, resulting in increased engine The LM6000 PC LPC is a five-stage, axial-
efficiency. The VIGV system consists of 43 flow compressor. The LPC features a five-
stationary leading edge vanes and variable stage fixed stator.
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Provision is made for LPC discharge flow to The stage 4 stator vanes are mounted in the
be bypassed through modulating bypass doors front frame and supported on the ID by a sup-
to assure adequate LPC stall margin at lower port structure that is bolted to the engine front
power settings and during large power reduc- frame.
tion transients.
4-5 Front Frame and Air
4-4.2 LPC Rotor Collector
Individual disks are used in stages 0 and 1. 4-5.1 Front Frame
Stages 2 through 4 of the LPC rotor are an
integral spool. Stages 0 through 3 blades also The front frame is a major structure that pro-
have squealer tips. vides support for the LPC rotor and the for-
ward end of the HPC rotor through the No.
Stage 0 blades are individually retained in the 1B, No. 2R, and No. 3R bearings. The frame
axial dovetail slots of the disk by a one-piece also forms an airflow path between the LPC
blade retainer. Stages 1 through 4 LPC blades and the HPC inlet. Front engine mount provi-
are retained in circumferential slots in the sions are located on the front frame 3:00 and
stage 1 disk and stages 2 through 4 spool. The 9:00 o'clock positions. Two pads are included
blade-retention features permit individual on the frame outer case for mounting HPC
blade replacement. Blades in stages 0 through inlet temperature sensors.
3 can be removed without removing the rotor.
The front frame is made from a high-strength
4-4.3 LPC Stator steel casting. Twelve equally spaced radial
struts are used between the hub and outer case
The stages 0 through 3 titanium stator vanes to provide support for the inner hub. Twelve
are individually replaceable. The vanes are variable-position bypass valve doors are
shrouded to reduce vane response to aerody- located on the outer wall for LPC discharge
namic forces. Wear strips are utilized between bleed.
the vane dovetails and the LPC casing slots.
The front frame contains the engine A-sump,
The Teflon-lined stages 0 through 3 case is which includes a thrust bearing (1B) and roller
horizontally split to allow top casing. This fea- bearing (2R) that support the LPC rotor, and a
ture facilitates vane and blade replacement, roller bearing (3R) that supports the forward
and allows removal without affecting the front end of the HPC rotor. Lubrication oil supply
frame air collector. The stages 0 through 3 and scavenge lines for the A-sump are routed
shroud are axially are split to aid in vane inside the frame struts. The inlet gearbox is
removal. Borescope ports are located at stages located in the A-sump with the radial drive
1, 2, and 3 for diagnostic inspection without shaft extending outward through the strut
disassembly. located at the 6:00 o'clock position.
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4-5.2 Bypass Air Collector 4-6.3 HPC Stator
The LPC bypass air collector is a duct The HPC stator consists of a cast stator case
attached to the front frame. It collects LPC that contains the compressor stator vanes. The
discharge air, vented through the LPC bypass inlet guide vanes and the stages 1 through 5
doors, and directs it overboard through pack- vanes can be rotated about the axis of their
ager-provided ducting. mounting trunnions to vary the pitch of the
airfoils in the compressor flow path. Vane air-
4-6 High Pressure Compressor foils in the remaining stages are stationary. All
fixed and variable vanes are non-interchange-
4-6.1 General Description able with other stages to prevent incorrect
assembly. The casing is split along the hori-
The LM6000 PC HPC is a 14-stage, axial- zontal split-line for ease of assembly and
flow compressor. It incorporates VIGVs and maintenance. The stages 1 and 2 vane shrouds
variable stators in stages 0 through 5 to pro- also support interstage rotor seals. The
vide stall-free operation and high efficiency shrouds are designed to allow the removal of
throughout the starting and operating range. either half of the compressor casing. There are
Stage 8 and at the compressor discharge air are 14 axial stations provided for borescope
used for combustor flame temperature control. inspection of blades and vanes.
Seventh and eleventh stage bleed air and com-
pressor discharge air are extracted for cooling 4-7 Compressor Rear Frame
and pressurization of the engine and bearing
sump components. The CRF consists of an outer case, 10 struts,
and the B- and C-sump housings. The outer
4-6.2 HPC Rotor case supports the combustor and fuel nozzles.
The hub provides support for a ball bearing
The HPC rotor consists of 14 stages. The stage and two roller radial bearings to support the
2 disk has an integral forward shaft and the midsection of the high pressure (HP) rotor
stages 11 through 14 spool has an integral rear system.
shaft.
Bearing axial and radial loads and a portion of
Stages 1 and 2 blades are individually retained
the first stage nozzle load are transmitted
in axial dovetail slots and the remaining
through the hub and 10 radial struts to the
blades are held in circumferential dovetail
case. The hub, struts, and outer casing are a
slots. These features allow individual blade
one-piece casting. The casting is welded to the
replacement without disassembly of the rotor.
fuel embossment ring and bolted to the aft
Stage 1 blades are shrouded at mid-span for case. This serves as the structural load path
the purpose of reducing vibratory stress. All between the compressor casing and the HPT
other blades are cantilevered from the rotor stator case. Seven borescope ports are pro-
structure. vided for inspection of the combustor, fuel
nozzles, and HPT. B- and C-sump service lines
are contained in, and pass through, the CRF
struts.
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4-8 Combustion System 4-9 High Pressure Turbine
4-8.1 General Description 4-9.1 General Description
The LM6000 PC gas turbine utilizes a lean The LM6000 PC HPT is an air-cooled, two-
premix combustion system designed for oper- stage design with demonstrated high
ation on natural gas fuel. efficiency. The HPT system consists of the
HPT rotor and the stages 1 and stage 2 HPT
The single annular configuration (SAC) nozzles.
enables the combustor to operate in uniformly
mixed, lean fuel to air ratio (premix mode) 4-9.2 HPT Rotor
across the entire power range, minimizing
emissions even at low power. The HPT rotor assembly consists of the stage
1 disk and integral shaft, a conical impeller
4-8.2 Single Annular Combustor spacer with cover, a thermal shield, and a
stage 2 disk. Forward and aft rotating air seals
Key features of the single annular combustor are assembled to the HPT rotor and provide
are the rolled-ring inner and outer liners, the air-cooled cavities around the rotor system.
low-smoke-emission swirl-cup dome design, An integral coupling nut and pressure tube are
and short burning length. This short burning used to form and seal the internal cavity. The
length reduces liner cooling air consumption rotor disks and blades are cooled by a continu-
which improves the exit temperature pattern ous flow of compressor discharge air. This air
factor and profile. The swirl-cup design serves is directed to the internal cavity of the rotor
to lean-out the fuel/air mixture in the primary through diffuser vanes that are part of the for-
zone of the combustor. This eliminates the for- ward seal system.
mation of the high-carbon visible smoke that
can result from over-rich burning in this zone. The stage 1 disk/shaft design combines the
rotor forward shaft and stage 1 disk into a one-
4-8.3 Ignition System piece unit. Torque is transmitted to the com-
pressor rotor through an internal spline at the
The ignition system produces the high-energy forward end of the disk/shaft. The stage 1
sparks that ignite the fuel/air mixture in the blades fit into axial dovetail slots in the disk.
combustor during starting. The system con- The stage 2 disk incorporates a flange on the
sists of one off-gas turbine mounted ignition forward side for transmitting torque to the
exciter, one lead, and one spark igniter. Once stage 1 disk. An aft flange supports the aft air
ignition occurs, combustion becomes self-sus- seal and the integral coupling nut and pressure
taining and continues without the spark ignit- tube. Stage 2 blades fit into axial dovetail slots
ers. in the disk.
Internally cooled turbine blades are used in
both stages. Both stages of blades are cooled
by compressor discharge air flowing through
the blade shank into the airfoil.
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The cone-shaped impeller spacer serves as the The turbine shrouds form a portion of the
structural support between the turbine disks. outer aerodynamic flow path through the tur-
The spacer also transmits torque from the bine. They are axially aligned with the turbine
stage 2 disk to the stage 1 disk. The catenary- blades and form a pressure seal to minimize
shaped thermal shield forms the outer portion HP gas leakage around tips of the blades.
of the turbine rotor cooling air cavity and
serves as the rotating portion of the interstage The interstage seal is composed of six seg-
gas path seal. ments bolted to the inner flange at the nozzle
segments. The sealing surface consists of a
4-9.3 Stage 1 HPT Nozzle two-step honeycomb seal that mates with the
rotating thermal shield. The interstage seal is
The stage 1 HPT nozzle consists of 23 two- designed to minimize leakage of core gas flow
vane segments bolted to a nozzle support around the stage 2 nozzle.
attached to the hub of the CRF.
4-10 Low Pressure Turbine
Compressor discharge air is used to cool the
nozzle vanes and support bands to maintain 4-10.1 General Description
the metal temperatures at the levels required
for extended operating life. The LPT drives the LPC and load device using
the core gas turbine discharge gas flow for
4-9.4 Stage 2 HPT Nozzle energy. The principal components of the LPT
module are a five-stage stator, a five-stage
The stage 2 HPT nozzle assembly consists of rotor supported by the No. 6R and No. 7R
24 two-vane stage 2 nozzle segments, stages 1 bearings, and a cast TRF supporting the stator
and 2 HPT shrouds and shroud supports, HPT casing and the No. 6R and No. 7R bearings.
stator support (case), and interstage seals. The
nozzle vanes are internally cooled by HPC 4-10.2 LPT Rotor
eleventh-stage air.
The LPT rotor assembly drives the LPC
The stage 2 nozzles are supported by the stage through the LP mid-shaft and drives a load
1 shroud support. They are also bolted to the through either the mid-shaft or from an aft
stage 2 shroud support forward leg, which is drive adapter on the rear of the LPT rotor. The
attached, by a flange, to the outer structural LPT rotor assembly consists of five stages of
wall. The stage 1 shroud system features seg- bladed disks and a shaft subassembly. The
mented supports and shroud segments to rotor is supported by the No. 6R and No. 7R
maintain turbine clearance. bearings in the D- and E-sump of the TRF.
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Each LPT rotor stage consists of a bladed disk The stage 1 nozzle vanes provide capability
subassembly comprised of a disk, turbine for LPT inlet instrumentation. Holes are pro-
blades, blade retainers, interstage air seals, vided for thermocouple probes and a single
assembly bolts, and balance weights. Integral pressure probe can be inserted. There are eight
flanges on each disk provide assembly bolt nozzles to provide for thermocouples, one for
holes in a low stress area of the disk. Blade a pressure probe, and four nozzle segments
retainers hold the turbine blades in the axial without instrumentation holes.
dovetail slots.
Seals minimize the air leakage around the
The turbine shaft assembly is a torque cone inner ends of the nozzles and shrouds mini-
coupled to the mid-shaft through a spline and mize air leakage over the tips of the turbine
is bolted to the stage 2 and stage 3 turbine disk blades.
flanges. It also provides the journal for the D-
and E-sump air oil seal and the No. 6R and 4-11 Turbine Rear Frame
No. 7R bearing interfaces. The rotating por-
tion of the balance piston system mounts on The TRF is a one-piece casting which pro-
the shaft, aft of the No. 7R bearing seals. vides the gas turbine exhaust flow path and the
Additionally, the aft shaft spline provides for supporting structure for the D- and E-sump,
driving the output load from the rear through the LPT rotor thrust balance assembly, the
the aft drive adapter. LPT rotor shaft, and the aft drive adapter.
Fourteen radial struts function as outlet guide
4-10.3 LPT Stator vanes to straighten the exhaust air flow into
the exhaust diffuser for enhanced perfor-
The five-stage stator assembly consists of a mance. Lubrication oil supply and scavenge
one-piece tapered 360° casing, five stages of lines for the D- and E-sumps and LPT rotor
interlocking tip shrouds, and a 12 segment speed sensors are routed through the struts.
LPT case external cooling manifold. Air-
cooled first stage nozzle segments with a bolt- The LPT rotor thrust balance system is
on pressure balance seal, four additional designed to maintain the axial thrust loading
stages of nozzle segments with bolt-on inter- on the No. 1B thrust bearing within design
stage seals, and instrumentation and borescope limits. The balance piston static seal is
ports also comprise the stator assembly. mounted to the TRF hub. Stage 11 HPC bleed
air is routed through three TRF struts to gener-
The LPT casing is the load-carrying structure ate the required axial loading through the rotor
between the HPT stator case and the TRF. The thrust balance system.
casing contains internal machined flanges that
provide hooks to support the nozzle segments
and stops to assure nozzle alignment and seat-
ing. Borescope inspection ports are provided
along the right side, aft looking forward (ALF)
from 2:30 to 4:30 o'clock positions at nozzle
stages 1, 2, and 4.
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4-12 Accessory Gearbox of the HPCR. The No. 4B bearing carries the
Assembly thrust loads for the HPR (HPC and HPT). The
No. 5R bearing supports the high pressure tur-
The accessories are driven from the high pres- bine rotor (HPTR) at its forward shaft.
sure rotor system by the inlet gearbox, a radial
drive shaft, and the transfer gearbox (TGB) The D- and E-sump houses the No. 6R and
assembly. The TGB is attached to the air col- No. 7R bearings. The No. 6R bearing supports
lector at the 6:00 o'clock position. The AGB the forward end of the low pressure turbine
(the accessory drive portion of the TGB rotor (LPTR) shaft. The No. 7R bearing sup-
assembly), located below the HPC casing, is ports the aft end of LPTR shaft and the bal-
driven from the TGB by a short horizontal ance piston system.
shaft. The starter, lube-and-scavenge pump, 4-3
VG hydraulic pump, and other accessories are Labyrinth-type seals control the flow of air
mounted on and driven by the AGB. into the sump areas to prevent excess oil con-
sumption. The A-sump drains into the TGB
4-13 Bearings through the same front frame strut that houses
the gearbox shaft. Oil is then scavenged
Eight bearings support the rotating compo- through the gearbox. The No. 4R/4B and No.
nents and the aerodynamic loads in the 5R bearing zones of the B- and C-sump are
LM6000 PC. Each rotating mass (the com- individually scavenged, as are the No. 6R and
pressor, turbine, and balance-piston system) is No. 7R bearing zones of the D- and E-sumps.
supported by roller bearings and axial thrust All sumps emit mist-carrying air and are
loads are carried by ball bearings. These bear- vented to a packager-supplied air/oil separator.
ings are located in the A-, B-, C-, D-, and E-
sump areas. Sump areas and bearing locations 4-14 Low Pressure Rotor Balance
are shown in figure 4-3. Piston System
The A-sump houses the No. 1B, No. 2R, and The balance piston system is designed to con-
No. 3R bearings. The No. 1B bearing is a ball- trol thrust loading on the No. 1B bearing.
type thrust bearing that carries the thrust loads These loads are imposed by LPC and LPT and
for the LPR (LPC and LPT). The No. 2R bear- vary with output power. Forward axial loads
ing supports the low pressure compressor are applied by varying air pressure in the bal-
rotor (LPCR) and the No. 3R bearing supports ance piston air cavity to maintain thrust loads
the high pressure compressor rotor (HPCR) within the capability of the bearing. Air pres-
forward shaft. sure at the balance piston cavity is maintained
at the correct level by the off-engine electronic
The B- and C-sump houses the No. 4R bear- control and the hydraulically activated balance
ing, the No. 4B bearing, and the No. 5R bear- piston valve.
ing. The No. 4R bearing supports the aft shaft
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Figure 4-3 Sump Areas and Bearing Locations
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5 CHAPTER 5
LM6000 PC Model System Descriptions
5-1 Purpose and Scope 5-2 Variable-Geometry Control
System
This chapter provides physical and functional
descriptions of the various secondary systems The VG control system includes the follow-
that are part of the LM6000 PC Model gas ing:
turbine.
• Variable inlet guide vane (VIGV) system
Systems described in this chapter include:
• Variable bypass valve (VBV) system
• Variable-geometry (VG) systems
• Variable stator vane (VSV) system
• Fuel systems
• Gearbox assemblies The VG control system consists of the VG
hydraulic pump, a hydraulic control unit
• Starter system (HCU) which houses torque motor-positioned
hydraulic servos for porting fluid at regulated
• Lube system pressure, two VIGV actuators, six VBV actua-
tors, and two VSV actuators. The VG hydrau-
• Sensors and indicating systems
lic pump is a fixed-displacement design which
• Ignition system supplies pressurized lube oil to the HCU for
delivery to the actuators.
• Bleed system
Positioning of the VIGVs, VSVs, and VBVs is
• Engine control unit (ECU) scheduled by packager-supplied control sys-
tem electrical inputs to three separate servo
• Low pressure rotor balance piston system
valves in the HCU, which is mounted on the
• Water-wash system VG hydraulic pump. Position feedback to the
control is provided by linear variable differen-
• Air system tubing and frame strut func- tial transformers (LVDTs) integral to the indi-
tions vidual system actuators.
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5-1
Figure 5-1 VIGV System
5-2.1 VIGV System control VIGV position by means of closed-
loop scheduling of VIGV actuator position,
The VIGV assembly is located at the front of based on LPC inlet temperature (T2) and high
the low pressure compressor (LPC). It allows pressure compressor (HPC) discharge static
flow modulation at partial power, resulting in pressure, (PS3) corrected to gas turbine inlet
increased engine efficiency. The VIGV system pressure conditions (P0).
consists of 43 stationary leading edge vanes
and variable trailing flaps. See figure 5-1. The 5-2.2 VBV System
variable flaps can be rotated from -10 degrees
open to +60 degrees closed by means of an The VBV system is located in the front frame
actuation ring, which is driven by twin assembly. This system is used to vent LPC dis-
hydraulic actuators at the 3:00 and 9:00 charge air overboard through the LPC bleed
o'clock positions. Normal engine operation is air collector in order to maintain LPC stall
approximately -5 degrees open (full power) to margin during starting, partial power opera-
+35 degrees closed (idle power). The flaps tion, and large power transients. The VBV
will also close during large power reductions system consists of 12 variable-position bypass
to quickly reduce the LPC flow rate in order to valves, six VBV actuators (two with LVDTs),
maintain the LPC stall margin. Both actuators six actuator bellcranks, 12 VBV door
are equipped with LVDTs. The packager-sup- bellcranks, and an actuation ring; see
plied control is designed to provide excitation figure 5-2.
and signal conditioning for both LVDTs and to
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5-2
Figure 5-2 VBV System
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Actuators are installed at the 1:00, 3:00, 5:00, 5-3 Fuel Systems
7:00, 9:00, and 11:00 o'clock positions on the
engine. The six actuators are positioned with This section provides functional descriptions
one VBV door on each side of each actuator. of the fuel systems included as standard equip-
The actuators, the actuation ring, and the VBV ment with the LM6000 PC model.
doors are mechanically linked by bellcranks
and pushrods. The actuator positions the actu- Simplified schematics of engine fuel system
ation ring, which opens and closes the VBV hardware are provided in figures 5-4, 5-5, 5-6,
doors. The 5:00 and 11:00 o'clock position 5-7 and 5-8.
actuators are equipped with integral LVDTs
for position indication. The packager-sup- Engine hardware includes fuel, water and/or
plied control is designed to provide excitation steam manifolds and feeder tubes, and fuel
and signal conditioning for both LVDTs and to fuel/steam nozzles mounted externally on the
control VBV position by means of closed-loop engine. Dual-fuel and liquid fuel models, with
scheduling of VBV actuator position, based on or without NOx suppression, include an off-
LPC inlet temperature (T2) and high pressure engine liquid fuel pressurizing valve.
(HP) rotor speed corrected to inlet conditions
Major fuel system components are shown in
(XN25R2).
table 5-1. Refer to the Illustrated Parts break-
5-2.3 VSV System down, GEK 105060, for exact configurations.
The VSV system is an integral part of the HPC The components listed in table 5-1 provide the
stator, consisting of two VSV actuators and flexibility to configure the engine for opera-
levers, actuation rings, and linkages for each tion on a variety of fuels and the option of
VSV stage. See figure 5-3. using water or steam to suppress NOx emis-
sions.
The LM6000 PC model gas turbine module is
equipped with two actuators on the VSV sys- 5-3.1 Gas Fuel Systems
tem, one at the 3:00 o'clock position and one
5-3.1.1 Systems for Standard Natural
at the 9:00 o'clock position. Each actuator
Gas
incorporates an integral LVDT. The packager-
supplied control is designed to provide excita- Natural gas fuel systems are available for use
tion and signal conditioning for both LVDTs with or without water or steam systems for
and to control VSV position by means of NOx suppression. Figure 5-4 is a simplified
closed-loop scheduling of VSV actuator posi- schematic of a natural gas fuel system with
tion, based on corrected HP rotor speed water injection for NOx suppression.
(XN25R). Figure 5-5 shows a simplified natural gas fuel
system schematic with steam for NOx sup-
pression.
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Table 5-1 Fuel System Components
Fuel System Manifolds Nozzle Type
Gas Gas manifold only Gas only
Gas/Water Gas and water manifolds Gas/water
Liquid Primary and secondary manifolds Liquid water with off-engine
pressurizing valve system
Liquid/Water Primary manifold, secondary manifold, Liquid water with off-engine
and water-mixing tee pressurizing valve system
Dual-Fuel/Water Primary manifold, secondary manifold, Dual-fuel with off-engine liquid fuel
and gas manifold pressurizing valve system
Gas/Steam Gas manifold and steam manifold Gas/Steam
Dual Gas Standard natural gas and medium BTU Dual Gas
gas manifolds
CAUTION Failure to provide necessary The minimum temperature of the gas fuel sup-
purge of fuel system components could result plied to the gas turbine shall be 50°F (27.8°C)
in fuel system hardware failure from back- greater than the saturated vapor temperature of
flow of combustion products. the gas supply pressure. The temperature of
the gas fuel should not exceed 300°F
The use of fuels that do not comply with gas (148.8°C) at the gas manifold inlet.
fuel specification MID-TD-0000-1,
Appendix A1, can cause severe damage to the The requirements for gas fuel are provided in
engine. Inquires concerning fuels that do not Appendix A1 in Volume I of this manual. The
meet requirements should be directed to the use of unapproved fuels can cause severe
packager. damage to the engine. Inquiries concerning
fuels should be directed to the packager.
During periods of operation without steam
injection, it is necessary to purge the fuel noz-
5-3.1.2 System for Medium BTU Gas
zle steam manifold. The recommended
method is to purge the manifold with CDP For medium BTU fuels with lower heating
manifold air extracted through a low delta P values in the range of 450-650 BTU/SCF, a
check valve. dual gas fuel system is available.
Note that, at shutdown, residual gas in the
Figure 5-8 is a schematic of the dual gas fuel
engine gas manifold and the packager's lines
system. The system is comprised of 30 fuel
downstream of the shutoff valves will vent
nozzles, with provisions for (1) injecting stan-
into the gas path and overboard via the engine
dard natural gas for starting and low power
flowpath and the exhaust ducting.
and (2) injecting medium BTU gas for opera-
The LM6000 PC fuel system includes fuel tion between approximately 50 percent power
manifolds, flexible fuel hoses, and 30 fuel and baseload.
nozzles.
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Figure 5-3 VSV System
During start to core idle natural gas, meeting 5-3.2 Liquid Fuel Systems
requirements of Appendix A1, is supplied to
the engine through the starting gas circuit Liquid fuel systems are available either with
through interface F3. or without water injection for NOx suppres-
sion. Figure 5-6 is a simplified liquid fuel sys-
After a 10-second dwell at core idle, medium tem schematic utilizing water injection. These
BTU gas is introduced to the main fuel circuit configurations have primary and secondary
through fuel supply manifold F1 and the gas liquid fuel circuits, as shown in figures 5-6
turbine operates on a mixture of natural gas and 5-7. They use an off-engine, base-
and medium BTU fuel. mounted valve. Both primary and secondary
manifolds and fuel nozzle feeder tubes, and
As power is increased from core idle to syn- fuel nozzles are mounted on the engine. There
chronous idle to about 50 percent power, a are two fuel supply points on the engine for
gradual transition is made from a combination these systems (one each for primary and sec-
of natural gas and medium BTU gas to 100 ondary).
percent medium BTU gas. When the natural
gas is shut off, a purge valve opens and
medium BTU gas flows into the starting gas
circuit, providing purge of that circuit.
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Figure 5-4 Gas Fuel System with Water NOx Suppression (Sheet 1 of 2)
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Figure 5-4 Gas Fuel System with Water NOx Suppression (Sheet 2 of 2)
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Figure 5-5 Gas Fuel System with Steam NOx Suppression (Sheet 1 of 2)
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Figure 5-5 Gas Fuel System with Steam NOx Suppression (Sheet 2 of 2)
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Figure 5-6 Liquid Fuel System With and Without NOx Suppression (Sheet 1 of 2)
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Figure 5-6 Liquid Fuel System With and Without NOx Suppression (Sheet 2 of 2)
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Figure 5-7 Dual Fuel System with Water NOx Suppression (Sheet 1 of 2)
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Figure 5-7 Dual Fuel System with Water NOx Suppression (Sheet 2 of 2)
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Figure 5-8 Dual Gas Fuel System Schematic (Sheet 1 of 2)
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Figure 5-8 Dual Gas Fuel System Schematic (Sheet 2 of 2)
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The primary fuel circuit is used for starting. It CAUTION Failure to provide necessary
provides a more precisely metered fuel flow purge of fuel system components could result
that ensures a proper fuel/air mixture. The in fuel system hardware failure from back-
presence of the proper fuel/ air mixture flow of combustible products.
ensures proper ignition and burning, which
When operating on gas fuel without water
prevents over-temperature problems and
injection, the primary and secondary liquid
flameout. The secondary fuel circuit provides
fuel manifolds are to be purged with gas fuel.
fuel during operation at normal power settings
Care must also be exercised to ensure proper
above core idle.
venting of natural gas, which is present in the
At shutdown, residual liquid fuel in the engine liquid drain system, when the engine is shut
fuel manifolds and the packager-supplied lines down.
between the fuel manifolds and the off-engine The gas manifold must be purged during liq-
fuel pressurizing valve must be drained. uid operation. This is required to prevent cok-
ing of the feeder tubes and/or gas fuel nozzles.
The use of fuels that don't comply with the liq- The purge line must include a double block
uid fuel specification MID-TD-0000-2, and bleed system to prevent injection of natu-
Appendix A2, can cause severe damage to the ral gas into the engine compressor discharge.
engine. The minimum acceptable liquid fuel
temperature is 35°F (1.6°C) or the temperature Fuel quality for the liquid and gas dual-fuel
to meet the viscosity and wax requirements of system is the same as for liquid or gas only.
MID-TD-0000-2, Appendix A2, whichever is
5-3.4 Liquid Fuel Pump and Filter
greater. Inquiries concerning fuels that do not
meet the requirements should be directed to The optional GE-supplied fuel pump/filter
the packager. consists of a two-element centrifugal/positive
displacement pump with an integral relief
5-3.3 Dual-Fuel System
valve and high-pressure filter. It is mounted
The dual-fuel (liquid fuel/natural gas) system directly on the engine accessory gearbox or on
is available with water injection for NOx sup- a purchaser-supplied electric motor with a
pression. Figure 5-7 shows a simplified dual- speed-increasing gearbox.
fuel system schematic utilizing water injection The centrifugal and positive displacement
for NOx suppression. pump elements are in series with the integral
relief valve, which is set for 1,350 psid
Gas fuel nozzles and the gas side of the dual
(9,307.9 kPa differential). The relief valve dis-
fuel nozzles have the same pressure flow char-
charges back to the inlet of the positive dis-
acteristics. Similarly, the liquid fuel circuits on
placement pump element. The high-pressure
dual fuel nozzles exhibit the same characteris-
filter, which mounts on the side of the fuel
tics as the liquid fuel circuits on liquid/water
pump, is a 46 micrometer “last chance” type
nozzles.
filter with minimal dirt-carrying capacity. The
filter also contains a bypass valve that causes
the fuel flow to bypass the filter if the pressure
drop exceeds 35 psid (241.3 kPa differential).
See figure 5-9.
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The fuel pump/filter assembly contains the The maximum allowable flow from the pilot
following three main ports: pressure port is 600 lb/hr (272.2 kg/hr). It is
subtractive from the pump main discharge
• Fuel inlet: 2.0 in (50.8 mm) tubing size flow.
5-3
• Fuel discharge: 1.0 in (25.4 mm) tubing 5-3.5 Liquid Fuel Handling
size
Sound procurement, proper transportation,
• Fuel bypass return: 1.0 in (25.4 mm) tub- and appropriate treatment of liquid fuel with
ing size the objective of meeting the GE liquid fuel
specification MID-TD-0000-2, Appendix A2,
The fuel supplied to the pump inlet shall meet are critical to gas turbine component life. Vari-
the following requirements: ous liquid fuel contaminants can cause differ-
ent problems within a gas turbine, but the most
• Quality: GE Specification
common contamination is from high levels of
MID-TD-0000-2, Appendix A2,
sodium. Sodium, or sodium in conjunction
• Filtration: 20 micrometers absolute with sulfur, can lead to severe premature hot
section distress. A rigorous fuel cleanliness
• Maximum temperature: 150°F (65.5°C) plan must be implemented daily to assure
trouble free operation of any gas turbine over
• Pressure: 5-50 psig (34.5-344.8 kPa gage) its operating life.
• Minimum temperature: 20°F (-6.6°C) Lessons learned have established good prac-
above wax point of the fuel tices in the transportation, handling, and deliv-
ery of the fuel to the gas turbine. It is critical
• Viscosity: 0.5 centistokes minimum to the trouble free operation of the gas turbine
that these practices be maintained at all times.
To prevent cavitation damage to the pump in Fuel analysis at the refinery is insufficient to
the event of an emergency shutdown, the assure that fuel will be delivered to the operat-
action of the fuel system shutoff valves, ing site in a condition consistent with the GE
installed in the pump supply and discharge specification. Transportation can introduce
lines, should be sequenced. The discharge contaminants. Poor storage practices, or treat-
shutoff valve is first to be actuated, followed ing facility malfunction, can increase the risk
by closure of the inlet shutoff valve, after a of contaminants. Lack of attention to detail
delay of approximately 15 seconds. can result in expensive to repair damage to hot
section hardware and costly plant outages in a
The bypass return fuel from the fuel metering short period of time.
valve inlet should be connected to the pump
bypass return port. The pump is capable of True distillate fuel has low water, dirt, and
accepting 100 percent of the fuel pump dis- trace metal contaminant levels, as refined,
charge flow at a maximum pressure of which can be maintained with careful trans-
100 psig (689.5 kPa gage) and a maximum portation, handling, and storage. Most fuel
temperature of 250°F (121°C). contamination occurs during transportation.
Where there is a danger of contamination,
such as salt-bearing water, auxiliary fuel
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Figure 5-9 Optional Fuel Pump and Filter Flow Diagram
clean-up equipment should be provided to structed of corrosion resistant materials or
restore original fuel quality. Available purifi- appropriately lined to minimize internally
cation equipment includes centrifuged and formed contaminants. Fuel should not be
electrostatic dehydrators. In addition to poten- stored or handled in components high in cop-
tial hot corrosion from salt in the water accu- per or coated with zinc.
mulated in the bottom of a storage tank, water
Duplex, primary strainers (150-200 microme-
can cause other problems. Microorganisms
tend to grow at the water to fuel interface, gen- ter µm absolute) should be located between
the off-loading facility and the raw-fuel stor-
erating chemicals corrosive to metals in the
age tanks. Duplex, secondary filters
fuel system and slime that can plug fuel filters.
(50-100 micrometer µm absolute) should be
Liquid fuel supplied by barges, or other bulk located between the raw-fuel storage tanks
modes of transportation, should be pumped and the final fuel-treatment system. All fuel-
directly into raw fuel storage tanks and must storage tanks, whether raw or clean, must have
be conditioned/treated before being placed in inlets at bottom. All tanks, whether raw or
one or two clean fuel storage tanks from clean, should be provided with a floating suc-
which the gas turbine will be supplied. Redun- tion. The distance between the inlet and outlet
dant, clean fuel tanks are required in order to of each tank should be maximized.
provide for a primary “settled” fuel supply, as
After filling any tank, or adding fuel to it, a
well as for preventative maintenance to allow
settling time of 24 hours should be allowed
for tank repair and/or cleaning with minimum
before taking fuel from that tank. Initially,
downtime. Storage tanks should be con-
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water and sludge should be drained from all after the above recommendations have been
storage tanks on a daily basis. After experi- implemented, indicate that the fuel system
ence is gained with a given fuel, and fuel does not provide fuel per the guidelines, the
source, the frequency of draining may be customer must change his fuel source or mod-
adjusted by the customer. ify the fuel treatment system.
For each delivery, fuel samples should be 5-4 Gearbox Assemblies
taken and analyzed at the following locations:
The LM6000 PC Model transfer gearbox
1. At the refinery before loading. assembly consists of the transfer gearbox
(TGB) and accessory gearbox (AGB). It is an
2. At the port where the fuel is delivered
accessory drive system that is driven from the
before unloading.
high pressure rotor system by the inlet gear-
3. From the pipeline just upstream of the box and radial drive shaft. The TGB assembly
raw fuel storage tanks as the fuel is is supported by the bypass air collector and
being added to the tanks. provides mounting and drive provisions for
the following (figure 5-6):
When the fuel is treated/conditioned samples
should be taken and analyzed at both the inlet • Pneumatic or hydraulic starter that drives
and outlet of the fuel treatment system. Fuel the HP rotor system through the TGB
exiting the system must meet the fuel specifi- assembly
cation.
• Lube and scavenge pump
This should be confirmed before the treated
fuel is placed in the clean fuel storage tanks • VG hydraulic pump and HCU
After filling the clean fuel storage tanks, and
allowing a 24 hour settling time, fuel samples • Packager-supplied accessories, optional
should be taken and analyzed to assure that the GE-supplied fuel pump, and for manual
fuel discharged from these tanks meets the rotation of the HP rotor system during
fuel specification. borescope inspection
For all fuel sampling, sufficient samples (a 5-5 Starting System
minimum of 3) must be taken to assure that a
representative sample is obtained. Samples The starter drives the engine HP rotor system
should be taken at different levels in large vol- through the TGB assembly starter drive pad
ume tanks and at equally spaced time intervals (figure 5-10). The starter is required for start-
during fuel delivery or fuel treatment. To ing, water-wash, and when required, for
avoid contamination, all samples must be motoring the engine. The gear ratio of the
obtained in clean plastic bottles. Fuel samples starter to the HP rotor is approximately 0.96:1.
should be analyzed for ash, sulfur, vanadium, Optional air, gas, and hydraulic starters are
sodium, potassium, lithium, lead, calcium, and available from the packager. For information
entrained water per the ASTM procedure indi- on non-GE starters, refer to the packager's
cated in the MID-TD-0000-2 liquid fuel speci- manual.
fication, Appendix A2. If fuel samples taken,
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Figure 5-10 Transfer Gearbox Assembly
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5-5.1 GE Starter Usage engine may be motored at 1,200 rpm (approxi-
mately 15 psig [103.4 kPa gage]) for 2 min-
For GE-supplied starters, it is recommended utes. The pressure can then be increased to
the starter not be engaged unless the HPC 38 psig (262.0 kPa gage) and fuel and ignition
shaft is at rest. If necessary, engagement can systems can be energized at 1,700 rpm.
occur at normal windmilling speeds not to
exceed 300 rpm. Engagement of the starter at The GE-supplied air/gas starter duty cycles
XN25 speed of 300 rpm to 1,700 rpm must be are as follows:
avoided to prevent damage to the starter or
TGB assembly. • Starting
Nominal cutout speed for the GE-supplied – 45 seconds On, 2 seconds Off for any
starter is 4,600 rpm (XN25). During engine number of cycles or
starting, minimum acceptable starter output – 2 minutes On, 5 minutes Off for a
speed is 4,100 rpm. Maximum acceptable maximum of two cycles or
starter output speed is 4,900 rpm.
– 2 minutes On, 21 minutes Off for any
If air is used to drive the starter, it can be dis- number of cycles.
charged directly from the starter with no addi- • Motoring
tional piping. If natural gas is used, the
exhausted natural gas must be vented to a safe – 5 minutes On, 2 minutes Off for a
location. For either type of pneumatic starter maximum of two cycles or
supplied by GE, the starter lube system is part
– 5 minutes On, 18 minutes Off for any
of the engine system, allowing constant oil
number of cycles or
flow through the starter. For all other starters,
refer to the packager's manual. – 10 minutes On, 20 minutes Off for any
number of cycles. For 10 minutes of
5-5.2 Starter Duty Cycles motoring, maximum starter air inlet
temperature is 200°F (93.3°C).
For information on starter types other than
those described here, contact the packager. 5-5.2.2 Hydraulic Starter
5-5.2.1 Air and Gas Starters The hydraulic starter consists of a variable dis-
placement type hydraulic motor. Piston stroke
During a normal start, the starter is energized is controlled by a wobble plate, while dis-
for approximately 40-70 seconds. Air/gas con- placement is controlled by means of a pressure
sumption per start is approximately compressor. The starter is equipped with an
120-250 lb (54.4-113.3 kg), depending on the over-running clutch to prevent the motor from
medium and conditions. being driven by the HP rotor when the hydrau-
lic supply pressure and flow are reduced to
The maximum supply temperature is 475°F zero. Physical arrangement and starter perfor-
(246.1°C). Air or gas must be dry and filtered mance are shown in figures 5-11 and 5-12
to 40 micrometers nominal. To purge and go respectively.
directly into a start cycle without stopping, the
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Figure 5-11 Hydraulic Starter
Figure 5-12 Hydraulic Starter Performance
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The hydraulic supply and control system are There are no duty cycle limitations on the
supplied by the gas turbine packager. hydraulic starter, as long as the oil temperature
Figure 5-13 is a simplified schematic of a is maintained under 140°F (59.9°C). The
maximum cooling circuit oil temperature limit
typical packager-supplied system. The starter
is 200°F (93.3°C).
interfaces are identified as B1 through B5 in
figures 5-11 and 5-13. The hydraulic starter For starting, a minimum pressure drop of
requires a flow capability of 0-55 gpm 4,200 psi (28,958 kPa) is supplied. As starter
speed increases, the flow will increase
(0-208.20 l/min) of hydraulic fluid at a
from 0 to 55 gal/min (0 to 208.2 l/min). At
maximum differential pressure of 4200 psi 55 gal/min (0 to 208.2 l/min) flow, an internal
(28,957 kPa). The maximum starter inlet pressure compensator in the starter maintains
pressure (pump compensator pressure) is starter inlet pressure and accelerates the starter
4500 psig (31,026 kPa gage). A list of the while the hydraulic supply system maintains
starter manufacturer’s approved oil types is the 55 gal/min (208.2 l/min) flow. When the
found in DEB-101. The oil temperature to the gas turbine is fired, it will eventually attempt
to drive the starter above its maximum speed.
start circuit shall be between 32° and 200°F
At this point, an internal over-running clutch
(0° and 93.3°C). The oil shall be filtered to allows the gas turbine to continue to run at its
10 µm nominal (25 µm absolute). The maxi- maximum speed without driving the hydraulic
mum starter discharge pressure is 300 psig starter. The hydraulic supply system for the
(2068 kPa gage). The supply pressure shall be hydraulic starter should be shut down and
reduced to zero after the gas turbine attains cooling flow initiated. If the gas turbine is
4,000 to 4,600 rpm (XN25). Drive input unfired, such as for purge or compressor
cleaning, the starter speed will approach the
power for the hydraulic supply pump is
steady state speed of 1,900 to 2,200 rpm
approximately 180-200 horsepower. desired, by decreasing the pressure drop
The maximum flow through the starter across the starter or limiting fluid flow to less
cooling circuit is 3.5 gal/min (13.25 l/min) and than 55 gal/min (208.2 l/min).
the maximum allowable backpressure is The seal drain connection allows hydraulic
25 psig (172.4 kPa gage). The minimum fluid that has leaked across the starter carbon
allowable backpressure is 1.0 psig (6.9 kPa seal between the starter and the AGB to be
gage). A maximum 2.0 gal/min (7.6 l/min) ported outside the package. The drain is
flows between the starting circuit and the redundant with the AGB drain at the starter
cooling circuit once the starting circuit is pres- location. The maximum flow through the
surized. Filtration requirements are the same starter seal drain is 5.0 cc/hr and the maximum
as the supply circuit. The starter torque allowable backpressure is 1.0 psig (6.9 kPa
characteristic is shown in figure 5-12. gage).
Cooling flow to lubricate the internal clutch is
For new installations or where the start system
required during over-running conditions (once
has had maintenance performed, the hydraulic
the start circuit flow is stopped). Supply shall
system supply and cooling lines should be
be to the cooling supply interface and return
flushed until clean, without the starter
from the cooling return interface shown in
installed in the circuit. This should be accom-
figure 5-11. The circuit uses the same
plished by circulating fluid through the
hydraulic fluid used in the supply circuit.
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Figure 5-13 Typical Hydraulic Starter Schematic
system, including filters, at operating tempera- 5-6 Lube System
tures, pressure, and flows until the system is
free of debris. The filter elements should then 5-6.1 General Description
be changed and the starter installed.
Figure 5-15 is the lube system schematic. The
5-5.2.3 Gas Turbine Airflow During engine uses lubrication oil to:
Starter Operation
• Lubricate and cool the HP and low pres-
When operating on the starter, airflow through sure (LP) rotor bearings, sumps, and the
the gas turbine for exhaust duct purge can be inlet, transfer, and accessory gearboxes.
calculated using figure 5-14.
• Operate the actuators for the VIGV, VBV,
and VSV systems; 8th stage and compres-
sor discharge pressure (CDP) bleed valves;
and LP rotor thrust balance control valve.
• Maintain a supply of oil to the optional
pneumatic starter.
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Figure 5-14 Subidle Airflow
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Figure 5-15 LM6000 Gas Turbine Lube System Schematic
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The standard engine lube system components then be changed and the lube system con-
include the gearbox-driven engine lube oil nected to the gas turbine. See Chapter 7 for
supply and scavenge pump and the necessary specific recommendations.
on-engine piping for the HP and LP system
bearings and sumps, for the inlet gearbox, and Use of engine lubrication oil for purposes
for the TGB assembly. Oil supply and scav- other than described in this section must be
enge temperature sensors are included. The oil reviewed by GE M&IED.
temperature sensors are dual-element resis-
tance temperature detectors (RTD). Three chip 5-6.2 System Flows, Pressures, and
detectors are also included. One monitors the Temperatures
thrust bearing in the A-sump and one the
Table 5-2 provides the parameter values for
thrust bearing in the B-sumps. The third or
the oil supply and scavenge, actuator drain,
common detector monitors the remaining
and air/oil vents for use in troubleshooting
bearings.
possible operational problems. Total flow
The packager provides air/oil separator(s), from the oil tank to the engine and return is
lube oil, lube conditioning and storage mod- approximately 17 gal/min (1.7 l/sec) at rated
ule, and the necessary flexible lines to inter- power.
face with the engine at two locations. The lube
5-6.3 Oil Specification
conditioning and storage system includes the
lube oil supply filter(s), scavenge oil filter(s), Type II oil (MIL-PRF-23699) is the preferred
oil cooler, check valves, and the storage tank. lubricant for the LM6000 PC gas turbine. This
class of synthetic oil has a coking temperature
The lubrication oil may be used with a transfer
advantage of 20°F (11°C) to 50°F (28°C) over
gearbox assembly-mounted hydraulic pump to
Type I (MIL-PRF-7808). For details on
provide hydraulic pressure to operate pack-
approved oils, reference Appendix A6, Lubri-
ager-supplied fuel, water, and steam metering
cating Oil. Improved film effectiveness of
valves, required by the system as supplied.
Type II oil MIL-PRF-23699 at higher temper-
For new installations, following lube system atures also improves bearing life. Type I lubri-
maintenance, or after lube system component cant is not recommended for general use in the
failure, the package lube system lines should LM6000 PC Model. In applications where
be flushed until free of contamination. The very low temperature starting capability is
flushing should occur without the gas turbine required, Type I oil may be used provided the
installed in the circuit. Flushing is accom- ambient temperature is consistently lower than
plished by circulating fluid through the system 68°F (19.9°C). Any use of Type I oil requires
and filters at operating temperatures and pres- approval of M&IED for the specific site. Ref-
sures. Continue circulation until system filters erence Appendix A for further guidance on
are free of debris. The filter elements should acceptable lubrication oils.
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Table 5-2 Gas Turbine Lube/Scavenge System
Description Fluid Flow Pressure Temperature
Lube Pump Inlet Oil 10-18 gal/min 0-1.0 psig 100 to 120°F
(0.63-1.13 I/sec) (0-6.9 kPa gage) (37.7 to 48.8°C)
Lube Supply to Filter Oil 10-18 gal/min 32-110 psig 140 to 160°F
(0.63-1.13 I/sec) (220.6-758.4 kPa gage) (59.9 to 71.1°C)
Engine Lube Supply Oil 10-18 gal/min 27-68 psig 140 to 160°F
(0.63-1.13 I/sec) (186.1-468.8 kPa gage) (59.9 to 71.1°C)
Scavenge Discharge to Oil 10-18 gal/min 20-80 psig 175 to 275°F
Filter (0.63-1.13 I/sec) (137.8-551.5 kPa gage) (79.4 to 134.9°C)
Air 0.1-.27 lb/min 0-1.0 psig 175 to 275°F
(0.045-0.12 kg/min) (0-6.9 kPa gage) (79.9 to 134.9°C)
A-, B- and C-Sump Oil 0.1-0.5 gal/min
Vents (6-31 ml/sec)
Air 75-225 ft3/m 0-1.0 psig 175 to 275°F
(0-6.9 kPa gage) (79.9 to 134.9°C)
(2.12-6.37 m3/min)
D- and E-Sump Vents Oil 0.1-0.5 gal/min
(6-31 ml/sec)
Air 15-40 ft3/m 0-1.0 psig 175 to 275°F
(0-6.9 kPa gage) (79.9 to 134.9°C)
(0.42-1.13 m3/min)
Combined Actuators Oil 0-30 ml/hr 0-2 in. H2O 140 to 160°F
Drain (0-0.5 kPa) (59.9 to 71.1°C)
VG Servo Drain Oil 0-30 ml/hr 0-2 in. H2O 140 to 160°F
(0-0.5 kPa) (59.9 to 71.1°C)
Combined Accessory Oil 0-10 ml/hr 0-2 in. H2O 140 to 160°F
Pad Drain (0-0.5 kPa) (59.9 to 71.1°C)
D- and E-Sump Drains Oil 0-25 ml/hr
Air 0-65 ft3/m 0-3 psig 225 to 860°F
(0-20.7 kPa gage) (107.2 to 459.9°C)
(0-0.03 m3/sec)
Thrust Balance Valve Oil 0-30 ml/hr 0-2 in. H2O 140 to 160°F
Drain (0-0.5 kPa) (60 to 71°C)
Note: Data provided are normal expected values from idle to maximum power.
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5-6.4 Lube Subsystems An antistatic leak check valve is provided in
the packager's system to prevent oil drainage
5-6.4.1 Lube Supply Circuit from the tank into the engine during shutdown.
The oil flow from the supply element of the 5-6.4.2 Scavenge Oil Circuit
engine lube pump is approximately propor-
tional to the engine HP rotor speed. The pump Scavenge flow, an air/oil mixture, is approxi-
internal relief valve for the lube supply ele- mately proportional to HP rotor speed. Scav-
ments is set to open at 300 psid (2,068.4 kPa enge pump capacity is approximately three
differential) and bypass full flow (at maximum times that of the oil supply element.
speed) at 400 psid (2,757.9 kPa differential).
The pump requires a flooded inlet to maintain Oil returning to the tank is cooled and filtered
prime. Immediately following cold starts, oil to 3.0-6.0 µm absolute to maintain a clean
pressure at the pump inlet may be as low as 5.0 tank. The filter should include a bypass relief
psia (34.5 kPa absolute). Oil pressure at the valve and bypass alarm as described for the
pump inlet shall not be less than atmospheric lube supply circuit. The tank must be vented to
pressure when the oil temperature is at normal ambient through an air/oil demister.
operating conditions. Oil from the lube and
scavenge pump shall be filtered to 3.0-6.0 µm An oil pressure measurement fitting is pro-
absolute by packager-supplied off-engine fil- vided in the engine lube oil scavenge system.
ters before being returned to the engine lube Limits in Chapter 10 apply to pressures mea-
system. Filters include bypass relief valve with sured at this fitting.
an alarm to alert the operator to impending
5-6.4.3 Engine Drains
bypass. Oil filter pressure drop shall not
exceed 40 psid (275.8 kPa differential) at full In normal operation, the drains will have little
oil flow. or no oil flow.
Oil supplied to the engine should not contain The B- and C-sump drains into the LP recoup
more than 10 percent entrained air on a vol- vent line. Under normal conditions, insignifi-
ume basis. cant amounts of oil will be entrained in the LP
recoup air. In the event of sump seal oil leak-
An oil pressure measurement fitting is pro-
age, the LP recoup vent line may contain
vided in the engine lube oil supply system.
entrained oil. The D- and E-sump drains are
Limits in Chapter 10 apply to pressures mea-
expected to carry insignificant amounts of oil
sured at this fitting. An on-engine temperature
during normal operation. The sump drains are
sensor is provided for oil supply temperature
sized to handle full air/oil flow in the event of
measurement. Engine oil pressure is a function
seal oil leakage.
of HP rotor speed and oil supply temperature.
Refer to Chapter 8 for oil supply characteris-
tic. Chapter 10 provides requirements for pres-
sure and temperature instrumentation and
operation limits.
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A fluid drain collector system should be pro- The drain lines from the air/oil separator and
vided, as part of the installation, and should the oil collector, if present, should be sepa-
comply with all applicable regulations relating rately routed back to the lube storage tank
to environmental contamination or pollution. without any traps in the lines.
It is strongly recommended that provisions be
made to isolate the drain lines, when neces- 5-6.4.5 Lube and Scavenge Line
sary, to enable troubleshooting for excessive Cooling
drain fluid flow. The collector system must not
permit fluids to siphon back into the engine. After engine shutdown, the turbine rear frame
(lube supply and scavenge lines) and compres-
The TGB assembly drive pad seal drain is a sor rear frame (LP recoup line) will require
manifold drain for the fuel pump, the starter, packager-supplied vent air cooling to prevent
the lube/scavenge pump, the external shaft oil line coking. This cooling air flow enters fit-
seal on end of the lube/scavenge pump, and tings near internal lube piping and provides a
the forward accessory pad. cool air film around these lines and sump
walls.
The TGB assembly drain manifold fluid may
be lube oil, fuel, or starter hydraulic oil and Cooling flow at the gas turbine should be
cannot be returned to the lube storage tank. 120°F (48.9°C) or less and 25 psig (172.3 kPa
gage). The cooling flow must be supplied for a
5-6.4.4 Sump Vent Circuit minimum of 1.5 hours after shutdown from
idle to provide sufficient time for the frames to
The engine A-, B-, C-, D-, and E-sumps vent cool below the lube oil coking temperature.
to the packager-supplied air/oil separator sys- Emergency shutdown from high power
tem. The allowable vent pressures into the air/ requires a longer cooling period.
oil separator at full power should not exceed
2.3 psig (15.85 kPa gage). See figure 5-16 for Post-shutdown cooling air supply for the tur-
sump locations and figure 5-17 for a sump- bine rear frame struts and the low pressure
function diagram. recoup line should conform to the same air
quality requirements of gas turbine inlet air.
Oil entrained in the vent air is normally com- Discharge from the fan or blower may be
posed primarily of liquid oil droplets. These water vapor saturated air but no water droplets
oil droplets may constitute as much as or slugs are permitted. Entrained oil not to
0.5 gal/min (32 ml/sec) from each sump vent exceed 3.0 lb/min, by weight.
interface.
5-6.5 Sump Pressurization
The amount of oil vapor discharging from the
air/oil separator exhaust will vary with separa- All sumps are pressurized by LPC discharge
tor efficiency. The air/oil separator exhaust static air pressure. This airflow is of sufficient
should be located to minimize oil vapor inges- volume and pressure to maintain a positive
tion into the engine inlet system. Oil mist will airflow inward across the inner seals to the
cause compressor fouling and engine perfor- inner sump cavity. This positive airflow car-
mance loss. ries with it any oil on the seals, thus retaining
the oil within the inner cavity.
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Figure 5-16 LM6000 PC Engine Sumps and Main Bearing Locations
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Figure 5-17 Sump Function Diagram
Sump pressurization air enters the outer sump 5-6.7 Oil Consumption
cavity through a pressurizing port. This air
then passes across the oil seals into the inner Oil consumption is not expected to exceed
sump cavity, where it is vented to the air/oil 0.4 gal/hr (1.5 l/hr). Additional oil may be lost
separator. overboard through the engine sump vents,
depending upon the efficiency of the air/oil
Sump pressurization air also passes outward separator(s).
across the outer seals to the engine cavity.
5-7 Sensors and Indicating
5-6.6 Oil Mixing Systems
Mixing of oils MIL-PRF-23699 and This section describes the various engine-
MIL-PRF-7808 should be avoided. If mixing mounted sensors and indicating systems
does occur, the tank should be drained and ser- required for normal operation of the
viced as soon as possible. Mixing of different LM6000 PC Model.
brands of oil to the same specification should
be accomplished by topping off the tank with 5-7.1 Speed Indication
new brand.
Two pairs of speed sensors (two per system)
are provided to monitor low pressure turbine
(LPT) rotor speed (XNSD) and HP rotor speed
(XN25).
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5-7.2 LP Rotor Speed 5-7.5 Temperature Sensors
The engine is equipped with two reluctant- 5-7.5.1 LPC Inlet Air Temperature (T2)
type speed sensors, mounted in the turbine
rear frame at struts No. 4 and 12. These sen- The engine is equipped with a probe to mea-
sors detect and measure the tooth-passing fre- sure the LPC inlet total temperature (T2) and
quency of a toothed sensor ring attached to the inlet total pressure (P2). The probe contains a
LPT rotor shaft. Each sensor has an integral dual-element RTD with an integral lead termi-
lead which terminates on the No. 4 electrical nating at the No. l electrical panel.
panel.
5-7.5.2 HPC Inlet Air Temperature
5-7.3 HP Rotor Speed (T25)
The engine is equipped with two reluctance- The engine is equipped with a probe to mea-
type speed sensors mounted in the AGB sec- sure the HPC inlet total temperature (T25) and
tion of the TGB assembly for sensing HP rotor the inlet total pressure (P25) of the high pres-
speed. The speed signal is produced by sens- sure compressor. The probe contains a dual-
ing passing gear teeth frequency on a spur element RTD with an integral lead terminating
gear in the accessory gearbox section. Har- at the No. 2 electrical panel.
nesses are routed to the No. 2 electrical panel.
5-7.5.3 HPC Discharge Temperature
5-7.4 Vibration Sensors (T3)
The engine is equipped with two accelerome- Two T3 sensors are included as standard
ters, one on the compressor rear frame (CRF) equipment. The T3 sensor is a dual-element
and one on the turbine rear frame (TRF). KP-KN thermocouple with readout capability
These accelerometers provide protection for each element. The integral leads are routed
against self-induced synchronous vibration. to the No. 3 electrical panel.
Each sensor is capable of monitoring both
high-speed and low-speed rotor vibration lev- 5-7.5.4 LPT Inlet Gas Temperature
els. Each accelerometer sensor has an integral (T48)
lead that is routed to one of the electrical pan-
Eight separate shielded KP-KN (type K) ther-
els CRF accelerometer to the No. 3 electrical
mocouple probes are installed on the LP tur-
panel; TRF accelerometer to the No. 4 electri-
bine stator case to sense LPT inlet
cal panel.
temperature. Each dual-element T48 sensor
Optional redundant engine accelerometers reads an average of the two elements for a
may also be included. total of eight control readings. Two flexible
harnesses, each connected to four of the
probes, are routed to connectors on the No. 4
electrical panel.
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5-7.5.5 Lube Supply and Scavenge 5-7.6.3 LPT Inlet Gas Total Pressure
Temperature (P48)
Seven dual-element platinum RTDs are pro- NOTE
vided as standard equipment on the engine, for
measurement of the lube oil supply and • The 17 cu in (278 cu cm) line volume
scavenge oil temperatures. These RTDs sense limits exist on the PS3 and P48 sensors.
temperatures of the bearing lube supply and Changes to the tubing should not be made
scavenge from the individual sumps (AGB, without consultation with the packager.
TGB/A, B, C, D, and E). The cables for these
• The P48 sensing lines, for flowpath pres-
RTDs are routed to the No. 2 electrical panel.
sure measurement, must include provision
Optional redundant RTDs may also be
for preventing water accumulation in the
included.
line. Contact your packager for the correct
5-7.6 Pressure Sensors configuration.
5-7.6.1 LPC Inlet Pressure (P2) The engine includes an LPT inlet gas total
pressure (P48) probe located on the right side
The engine is equipped with a probe which of the LPT stator case.
measures LPC inlet total temperature (T2) and
which provides a tap to measure LPC inlet 5-7.6.4 Additional Pressure
total pressure (P2). The P2 tap is a threaded Parameters
boss that may be connected by a tube or hose
Additionally, the LM6000 PC Model includes
(supplied by the packager or user) to a trans-
provisions for measurement of the following
ducer. The probe is located in the VIGV case
pressure parameters:
which also contains provisions for a second
optional probe. NOTE
5-7.6.2 HPC Inlet Pressure (P25) • The 17 cu in. (278 cu cm) line volume
limits exist on the PS3 and P48 sensors.
The engine is equipped with a probe which Changes to the tubing should not be made
measures HPC inlet total temperature (T25) without consultation with the packager.
and which provides a tap to measure HPC
inlet total pressure (P25). The P25 tap is a • The PS3 sensing lines, for flowpath pres-
threaded boss that may be connected by means sure measurement, must include provision
of a tube or hose (supplied by the packager or for preventing water accumulation in the
user) to a transducer. This probe is located in line. Contact your packager for the correct
the front frame which also contains provisions configuration.
for a second optional probe.
• HPC inlet static pressure (PS25)
• HPC discharge static pressure (PS3); two
locations
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• Thrust balance cavity pressure (PTB) 5-7.9 Flame Sensors
• Balance piston pressure reference (PBPV) An ultraviolet flame detector indicates the
presence, or loss of flame, in the engine com-
Of these, PS25 and PBPV can be used for con- bustion system for engine control system logic
dition monitoring or troubleshooting. The use in sequencing and monitoring. The flame
remaining two (PS3 and PTB) are vital to detector hardware consists of two ultraviolet
engine operation and are an integral part of the sensor assemblies and two flame viewing win-
packager-supplied control system. For these dow assemblies mounted on two holes in the
parameters, the packager is responsible for compressor rear frame. The flame sensors
sensor leads and readout devices. come equipped with cooling cans and integral
leads, which are connected directly to the
P0, which is located in the inlet to the gas tur- packager-supplied signal conditioner. Cooling
bine, is critical to the scheduling of the VIGV air for the system is packager-supplied and
system and load limiting. The sensor reads must be kept on for a minimum of 30 minutes
slightly less than ambient when functioning following a normal shutdown.
properly in a clean inlet. Failure to calibrate
this reference using a calibrated ambient pres- 5-7.10 Thrust Balance Control System
sure gauge will result in performance loss.
The thrust balance control system consists of
5-7.7 Chip Detectors the on-engine VG hydraulic pump and an off-
engine mounted thrust balance control valve
The engine is equipped with electrical/mag- and actuator. Positioning of the thrust balance
netic remote-reading chip detectors in the control valve is scheduled by a purchaser-
TGB/A-sump, B-sump, and common scav- supplied control system electrical input to the
enge return lines. Optional chip detectors are valve mounted servo valve. Position feedback
available for use on the C-, D-, and E-sump is provided by two LVDTs integral with the
scavenge lines. actuator.
Each standard or optional chip detector indi- 5-8 Electrical System
cates chip collection when resistance across
the detector drops. Chip detector leads are The engine electrical system consists of the
connected to the No. 2 electrical panel. ignition system and the cabling for the control
and instrumentation. The system is designed
5-7.8 Variable-Geometry Position for high reliability and ease of maintenance by
utilizing integral lead sensors or on-engine
The positions of the LPC variable inlet guide
harnesses, which are terminated at one of four
vanes (VIGV), the LPC variable bypass valves
electrical connector panels mounted on the
(VBV), and the HPC VSV are provided to the
engine. See figure 5-18 for electrical panel
control and monitoring systems by indepen-
locations.
dent pairs of linear variable differential trans-
formers (LVDTs). Two actuators in each VG
system are equipped with LVDTs.
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Figure 5-18 LM6000 Electrical Panel Locations
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5-8.1 Ignition System ON and two start cycles within a 30 minute
period.
The ignition system consists of a high-energy
igniter, a high-energy capacitor-discharge 5-8.2 Cabling
ignition exciter, and an interconnecting cable.
A redundant ignition system that replaces a The LM6000 PC model is optionally supplied
plug in the compressor rear frame is also with electrical cables for interconnection
available. The ignition cables interconnect between the package-mounted junction boxes
directly between the package-mounted excit- and the engine. Each of the cables connects to
ers and the igniters, which are mounted on the the engine at one of five electrical panels, as
engine compressor rear frame. indicated in figure 5-18. Instrumentation leads
must be shielded, isolated from power leads,
During the start sequence, fuel is ignited by and run in conduits carrying only other very
the igniter, which is energized by the ignition low level leads. Figure 5-18 provides the iden-
exciter. Once combustion becomes self-sus- tification and panel designation for the cables
taining, the igniter is deenergized. The maxi- supplied as standard. Table 5-3 defines the
mum duty cycle is a maximum of 90 seconds abbreviated nomenclature used in figure 5-18.
Table 5-3 LM6000 PC Electrical Cable Panel Nomenclature
Abbreviation Nomenclature
AGB Accessory Gearbox
CRF Compressor Rear Frame
LVDT Linear Variable Differential Transformer
RTD Resistance Temperature Detector
TC Thermocouple
T/M Torque Motor
TGB Transfer Gearbox
TRF Turbine Rear Frame
T48 Low Pressure Turbine Inlet Temperature
T2 Low Pressure Compressor Inlet Temperature
T25 High Pressure Compressor Inlet Temperature
T3 High Pressure Compressor Discharge Temperature
VBV Variable Bypass Valve
VIGV Inlet Guide Vane
VSV Variable Stator Vane
XNSD Low Pressure Turbine Rotor Speed
XN25 High Pressure Rotor Speed
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5-8.3 Electrical Panels 5-10 Engine Control Unit
The LM6000 PC is equipped with four electri- The engine control unit (ECU) supplied by the
cal panels mounted on the engine. These pan- packager, performs the fuel, bleed, and vari-
els provide a convenient intermediate able-geometry scheduling, engine start and
interface point between the engine instrumen- stop sequencing, and data acquisition for sup-
tation sensors and the enclosure interface. port of the engine monitoring system. Alarm
Figure 5-18 illustrates the five panel locations. and shutdown logic is included in Chapter 10,
The advantages of these interface panels are as Troubleshooting.
follows:
5-11 Low Pressure Rotor Balance
• Simplified installation and removal of the Piston System
engine
A balance piston system has been included in
• Keyed or sized connectors to prevent
the aft end of the engine. See figure 5-19. The
incorrect mating
system is designed to provide the required
The positive-lock threaded connectors speci- thrust load on the No. lB bearing.
fied eliminate the need for safety wiring the
The balance piston system consists of the bal-
connectors.
ance piston disk, the balance piston casing,
5-9 Bleed System their associated seals, and the dome-shaped
cavity formed by these parts. This cavity is
Bleed air is available for customer use from pressurized by stage 11 HPC bleed air, con-
stage 8 or the discharge of the HPC. Extrac- trolled by a modulating valve mounted exter-
tion of HPC bleed air affects the performance nally on the TRF. The balance piston casing is
and available power output of the engine and attached to the aft inner hub of the TRF; the
should, therefore, be minimized. The flow balance piston disk is attached to the LPT
amounts described in the following para- shaft.
graphs are the maximum amounts of flow
available for any purpose. 5-12 Water-Wash System
5-9.1 Eighth Stage HPC Bleed A water-wash system can be provided by the
packager to remove contaminants that accu-
HPC bleed air is available from the 8th stage mulate in the LPC and HPC, resulting in a loss
of the HPC if required by packager-supplied of performance.
systems. In most applications, 8th stage bleed
There are two methods of water-washing
is limited to a maximum of 3.3 percent of HPC
available: crank-soak and on-line cleaning.
airflow.
Technique associated with a working water-
5-9.2 HPC Discharge Bleed wash system that maintains compressor effi-
ciency is very much dependent on site condi-
The engine is provided with HPC discharge tions. Each operator should, by testing, choose
bleed capability at the compressor rear frame. the proper fluid and wash frequency based on
HPC discharge bleed air flow under choked their plant economics. Water-wash recommen-
conditions is limited to a maximum of 4 per- dations and procedures are covered in
cent of HPC airflow. HPC discharge bleed is WP 4014 00.
unavailable in dual fuel and gas/steam fuel
system configurations.
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Figure 5-19 Low Pressure Rotor Balance Piston System
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5-13 Engine Airflow 5-14.5 Compressor Discharge
Pressure Bleed
A schematic representation of the internal and
external gas turbine air flows is shown in The CDP bleed manifold combines two com-
Chapter 4, figure 4-1. pressor case bleed ports into a single interface.
5-14 Air System Tubing and 5-14.6 High Pressure and Low
Frame Strut Functions Pressure Recoup
The HP recoup air is connected by manifolds
The LM6000 PC model has 11 major external
from the compressor rear frame struts 4 and 10
pneumatic tubing designs and three strut
to the LPT stage 1 nozzle area on the LPT
locations. The struts are located in the front
case. HP recoup air is used for cooling of the
frame, CRF, and TRF. See figures 5-20 and
aft position of the LPT stage 1 nozzle vanes.
5-21 for tubing locations and figure 5-22 for
LP recoup air is bled overboard from CRF
strut functions.
struts 5 through 8.
5-14.1 A-, B-, C-, D-, and E-Sump Vents
5-14.7 HPT Cooling
Two interfaces are provided to the customer
Stage 11 HPC bleed air is used for cooling the
for venting the three bearing sumps. These
stage 2 HPT nozzle. Four external tubes
vents direct the sump air/oil mixtures over-
extract stage 11 air from the compressor and
board so the customer can reclaim lubrication
are branched into two ports on the HPT case.
oil.
5-14.8 LPT Cooling
5-14.2 B- and C-Sump Pressurization
Stage 8 HPC air is routed through two mani-
LPC discharge air from the front frame is
folds to the stage 1 LPT nozzle for cooling its
directed through a single manifold to the CRF
leading edge cavity.
where it supplies pressurization air for the B-
and C-sump. 5-14.9 Passive Clearance Control
5-14.3 Balance Piston LPC discharge air is extracted at the front
frame and discharged through small holes in
Stage 11 HPC air is extracted near the 12:00
tubing that surrounds the LPT case. The cool-
o'clock position on the HPC case. This air is
ing air reduces LPT clearance resulting in
directed aft through a control valve into the
increased turbine efficiency.
TRF at struts 3 and 8 for supplying the balance
piston system cavity.
5-14.4 HPC Stage 8 Bleed
Stage 8 bleed air is extracted through holes
bored in the stator casing aft of the stage 8
vane dovetails. A manifold combines the two
HPC case ports into a single interface.
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Figure 5-20 LM6000 PC Gas Turbine - Left Side View
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Figure 5-21 LM6000 PC Gas Turbine - Right Side View
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Figure 5-22 LM6000 PC Gas Turbine - Strut Functions (Sheet 1 of 2)
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Figure 5-22 LM6000 PC Gas Turbine - Strut Functions (Sheet 2 of 2)
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5-15 SPRINT® System • 48 feeder tubes which deliver the air and
water to the nozzles
SPRINT® is an optional equipment system
which allows higher power operation for inlet • an extraction port to extract the atomizing
temperatures above 30°F (-1.1°C). SPRINT® air
operates as an intercooler by injecting a fine
water mist into the compressor airflow and The off-engine part of the system includes:
reduces the temperature of the air as it evapo-
• water supply pump, and metering device,
rates in the front compression system.
flow measuring and air and water control
Two versions of SPRINT® have been pro- on-off valves
duced. In early productions of SPRINT®, the
water mist injection is injected in the HPC • air supply lines from compressor extrac-
inlet airflow only, via nozzles mounted in the tion to SPRINT® air manifold
compressor front frame. In later versions
(referred to as enhanced SPRINT®) additional • a heat exchanger to cool atomizing air and
injection nozzles were added, in the radial heat water (initial models)
inlet volute, to enable LPC inlet injection
• pressure taps to sense manifold pressures
which provides additional evaporative cooling
and send to the control
benefits during hot-day operation. In the later
version, the inlet mist injection is disabled • accumulator to smooth flow and prevent
during potential below-icing conditions severe on-off transients
[T2<45°F (7.2°C)].
5-15.1 SPRINT® System with HP This system also requires a different control
Injection Only software from a standard LM6000PC engine.
Figure 5-23 is a schematic of the SPRINT® 5-15.2 SPRINT® Systems with LPC and
system. The water is atomized to a very fine HPC Inlet Injection
aerosol mist using atomizing air extracted
With the introduction of the later SPRINT®
from stage 8 of the HPC. SPRINT® water
configuration, the mist injection nozzles were
injection is automatically initiated only at Ps3
redesigned to eliminate need for the off-engine
values within 50 psi of the dry Ps3 schedule.
heat exchanger. Testing also showed that the
Reference Chapter 8 on operation of the
accumulator could be eliminated.
SPRINT® system.
The on-engine system is comprised of: Figure 5-24 is a schematic of the SPRINT®
systems with LPC and HPC injection capabil-
• 24 injector nozzles mounted in the com- ity. Figure 5-25 is a schematic without the off-
pressor front frame engine heat exchange system.
• two manifolds (air and water) mounted The on-engine system is comprised of:
forward of the air collector
• 24 injector nozzles mounted in the com-
pressor front frame
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• two manifolds (air and water) mounted • air supply lines from compressor extrac-
forward of the air collector tion to SPRINT® air manifold
• 48 feeder tubes which deliver the air and • pressure taps to sense manifold pressures
water to the nozzles and send to the control
• atomizing air supply line from the com- • 23 inlet volute mounted nozzles, inlet
pressor to the atomizing air manifold volute mounted
The off-engine part of the system includes: • an atomizing air manifold and supply pip-
ing
• water supply pump, and metering device,
flow measuring and air and water control • an inlet volute mounted water manifold
on-off valves
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Figure 5-23 SPRINT® System Schematic (Sheet 1 of 2)
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Figure 5-23 SPRINT® System Schematic (Sheet 2 of 2)
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Figure 5-24 SPRINT® Enhanced System Schematic (Sheet 1 of 2)
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Figure 5-24 SPRINT® Enhanced System Schematic (Sheet 2 of 2)
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Figure 5-25 SPRINT® 1 System W/O Heat Exchange System Schematic (Sheet 1 of 2)
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Figure 5-25 SPRINT® 1 System W/O Heat Exchange Schematic (Sheet 2 of 2)
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LM6000 PC ORIGINAL INSTRUCTIONS GEK 105059
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3 CHAPTER 6
Service and Support Requirements
6-1 Purpose and Scope If the gas turbine and fuel system are removed
from the enclosure in preparation for ship-
This chapter defines the following service and ment, the fuel system must be properly
support requirements associated with the drained and purged of gas or liquid fuel prior
LM6000 PC gas turbine. to removal as covered in WP 3010 00.
• Shipping 6-2.1 Engine Shipment
• Storage CAUTION Ensure crane is of sufficient lift-
ing capacity when moving shipping con-
• Installation/Removal tainer with engine installed, into and out of
truck.
• Auxiliary systems
a. The engine assembly is shipped in a metal
• Support services
container that measures 219 inches (556.3
• Maintenance cm) long by 102 inches (259.1 cm) wide
by 99.25 inches (252.1 cm) high. The
The information provided is general but not empty container weighs approximately
all-inclusive. References are made to other 11,000 pounds (4,990 kg). With the addi-
sections of this manual and to specific mainte- tion of the air ride (Soft Ride) kit installa-
nance work packages (WP) that cover these tion (SWP 3014 01), weight increases
topics in detail. approximately 2000 pounds (907 kg). The
container is equipped with shock mounts
6-2 Shipping to avoid damage to the engine bearings
The engine is shipped from the factory as a during shipment. It has a pressure relief
complete assembly, including the engine, fuel valve for controlled breathing, humidity
manifold, engine-mounted accessories, exter- indicators, and a desiccant container for a
nal configuration hardware, and engine controlled environment.
mounted sensors. The engine is shipped on an
b. Weight of the container and engine assem-
air ride tractor trailer or a conventional tractor
bly, as shipped from the factory, is approx-
trailer can be used if an air ride (Soft Ride) kit
imately 31,000 pounds (14,061 kg).
is installed onto the shipping container per
SWP 3014 01. The air ride (Soft Ride) kit is c. In the event that the engine requires repair
designed to reduce the possibility of bearing at a designated repair facility, it should
damage in engines installed in shipping con- be shipped to the facility in the shipping
tainers in areas where tractor trailers with air container. Installation of the engine in
ride suspensions may not be available. the shipping container is covered in
WP 3014 00.
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6-2.2 Low Pressure Turbine Module b. All aero engines (gas turbines and gas gen-
Shipping erators) are to be transported on air ride
tractor trailer or conventional tractor
a. The low pressure turbine (LPT) module, trailer with air ride (Soft Ride) kit installed
consisting of the LPT rotor, LPT stator, (SWP 3014 01) for the specific engine and
turbine rear frame, and aft drive adapter, shipping container. Aero engines are not
can be transported in a unique reusable approved for transportation by rail type
metal shipping container. This container is systems.
95 inches (241.3 cm) long by 88 inches
(223.5 cm) wide by 80.0 inches (203.2 cm) Notify GE of any unusual engine/container
high. Similar to the engine assembly con- shipping event such as dropped container
tainer, it is equipped with shock mounts to (with engine installed) or tractor trailer
avoid damage to the No. 6R and No. 7R accident. All special events require a
bearings during shipment. It has a pressure report to your GE representative for dispo-
relief valve for controlled breathing, sition of the gas turbine/gas generator.
humidity indicators, and a desiccant con-
tainer for a controlled environment. 6-2.4 Container and Engine Lifting
b. The weight of the container is approxi- GE recommends the following prior to lifting
mately 5,200 pounds (2,359 kg) empty and a LM6000 shipping container:
11,600 pounds (5,262 kg) loaded. Installa-
tion of the LPT module in the shipping a. Visually inspect lifting features for cracks.
container is covered in WP 3017 00.
b. If cracks noted, document and report fin-
NOTE Both the engine and LPT module con- dings to GE.
tainers can be air-shipped on the 747F, L1011,
or C130. The LPT module can also be air- c. If cracks noted, local weld repair is autho-
shipped on DC10CF, C130, A300C, and rized. Weld procedure is provided in
A310C/F aircraft. LM6000 Service Letter No. 6000-04-08.
6-2.3 Engine Shipping Container d. Utilize a Quad Sling of 144 inches
(3658 mm) minimum length (45 degrees
a. The shipping container described in standard practice) for lifting as indicated
paragraph 6-2.1 and shown in figure 6-1 is in figure 6-1, sheet 2.
equipped with a vibration-attenuation sup-
port system. It protects the engine from 6-2.5 Enclosure Shipping
damage when subjected to repetitive or
nonrepetitive loads at the container mount In the event that the engine is to be shipped
interface locations during transportation already mounted in the enclosure (package),
and handling. the design of that enclosure shall meet the
requirements listed above for the shipping
container.
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Figure 6-1 Engine Shipping Container (Sheet 1 of 2)
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Figure 6-1 Engine Shipping Container (Sheet 2 of 2)
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6-2.6 Highway Shipping Figure 6-2 illustrates the LM6000 PC mainte-
nance dolly. Use of the maintenance dolly is
CAUTION covered in WP 3012 00. A ground handling
dolly is available for transportation on-site.
• Shipment by rail transportation is not
Contact GE M&IAD for details of use.
acceptable. 6-1
• Shipping of the engine/container system 6-3 Storage
requires the use of a pneumatic suspen-
The engine is prepared for long-term storage
sion tractor and trailer for highway ship-
when shipped from the factory or from a
ment. A conventional tractor trailer can
repair facility. Long-term storage includes the
be used if an air ride (Soft Ride) kit is
following elements:
installed onto the shipping container.
When using a pneumatic suspension • Lubrication system is flushed with rust
tractor and trailer, the engine container preventative
shall be secured to the trailer in such a
manner that the shock-absorbing capa- • Inlet is covered
bility of the container is not disabled. Tie- • Air collector is covered
down points are provided on both sides of
the lower portion of the container, fore • Exhaust is covered
and aft. Failure to comply with this • Lines are connected or capped
requirement may result in damage to the
engine bearings. When using a conven- • Container is hermetically sealed and pro-
tional tractor trailer with an air ride (Soft vided with desiccant for humidity control
Ride) kit installed onto the shipping con-
tainer, the air ride (Soft Ride) boxes on Should temperature, pressure, and/or humidity
each corner of the gas turbine shipping conditions be such that the desiccant seen
container shall be secured to the truck through the container inspection port is blue,
trailer bed, using chains between the then the container must be serviced in accor-
trailer and tie down rings on the air ride dance with WP 3014 00.
(Soft Ride) box. Make sure the shipping
container is not directly chained to or in When an LM6000 gas turbine is to be stored
direct contact with the trailer bed or dam- for an extended period of time, precautions
age to the engine bearings may result. must be taken to preserve the gas turbine in
order to minimize exposure to atmospheric
6-2.7 On-Site Transportation corrosion. Details of preservation depend on
the duration of nonoperation and whether the
CAUTION If the engine is removed from gas turbine is being stored in an engine enclo-
the container or enclosure and transported sure or in a shipping container. Table 6-1 pro-
using the LM6000 PC maintenance dolly, vides a summary of these details. Refer to
speed during that movement should be lim- WP 3011 00 for details of precautions and
ited to a maximum of 2 mph. Failure to com- preservation procedures.
ply with this requirement may result in
damage to the engine bearings.
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Figure 6-2 Maintenance Dolly
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6-4 Installation/Removal • Engine Width: 84.7 inches (215.1 cm), air
collector upper flange
This section provides general descriptions of
• Engine Height: 80.7 inches (205.0 cm),
procedures and elements requiring consider-
LPT piping to Accessory Gearbox (AGB)
ation during installation and removal of the
low point
engine.
The estimated weight and center of gravity of
6-4.1 Installation/Removal Methods the engine with VIGV installed offered are
16,660 pounds (7557 kg) and axial station
Installation of the engine into, or removal 232.9 inches (5.92 m), respectively. See
from, the enclosure will normally be accom- table 6-2 for weights and centers of gravity of
plished by one of two methods listed below. the major components. Centers of gravity are
Installation and removal procedures are cov- axial station numbers; for reference, the VIGV
ered in WP 3010 00. forward flange (or inlet frame) station is
140.44 inches (3.567 m). All dimensions are
If the fuel manifolds or other fuel system com-
measured in the aft direction from the VIGV
ponents are shipped with the engine, the sys-
forward flange (or inlet frame).
tem must be properly drained and purged of
gas or liquid fuel consistent with regulatory 6-4.3 Engine Mount Attachments
requirements for hazardous materials prior to
installation in the shipping container. Separate Mounting attachments are provided in five
fuel system drain and purge requirements for places on the engine. The forward two mount
both ground and air shipment are included in points are located aft of the Low Pressure
WP 3010 00. Compressor (LPC) bypass air collector at the
3:00 and 9:00 o'clock positions.
• Overhead installation/removal through an
opening in the top of the enclosure a. The forward mount connections are
requires the use of an on-site or mobile accomplished by uniballs and pillow
crane and an adjustable beam. blocks supported by stanchions or a simi-
lar design, as shown in figure 6-3. These
• Side installation/removal requires the mounts are designed to provide support in
engine to be lifted using an adjustable all directions and are sized to accommo-
beam and the ground handling points, so it date axial thrust, operating torque, and
can be moved laterally into/from the vibratory loads. The two engine-mounted
enclosure. trunnions are not to be removed from the
engine; all hardware is packager-supplied.
6-4.2 Size/Weight
b. The turbine rear frame is equipped with
The following information is provided for
three mount attachments, as shown in
installation, removal, and on-site movement
figure 6-3. These mounts are designed to
planning.
provide for vertical and lateral support of
• Engine Length: 193.5 inches (491.5 cm), the engine.
Variable Inlet Guide Vane (VIGV) forward 6-2
flange to aft drive adapter
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Table 6-1 Engine Preservation Summary (Refer to WP 3011 00)
Timing: Less Than 30 Days Greater Than 30 Days
Inspection Requirement Inspection Requirement
Engine installed in package Inspect inlet Inspect inlet
Inspect exhaust Inspect exhaust
Inspect VBV duct (if accessible) Inspect VBV duct (if accessible)
Oil wet bearings (BRAYCO 599, or Oil wet bearings (BRAYCO 599, or
equivalent, required if preservation equivalent, required)
period greater than 15 days) Cover inlet (optional)
Cover inlet (optional) Cover exhaust (optional)
Cover exhaust (optional) Cover VBV (optional)
Cover VBV (optional) Oil wet bearings every 30 days
(BRAYCO 599, or equivalent,
required)
Engine installed in container Oil wet bearings (BRAYCO 599, or Preserve liquid fuel pump, if
equivalent, required if preservation installed
period greater than 15 days) Oil wet bearings (BRAYCO 599, or
Install desiccant equivalent, required)
Inspect desiccant every 30 days Install desiccant
If blue: Inspect desiccant every 30 days
No action required If blue:
If pink: No action required
Oil wet bearings within 14 days If pink:
Install new desiccant Oil wet bearings within 14 days
Install new desiccant
Engine installed in maintenance Oil wet bearings (BRAYCO 599, or Preserve liquid fuel pump, if
dolly or pedestal equivalent, required if preservation installed
period greater than 15 days) Oil wet bearings (BRAYCO 599, or
Cover inlet equivalent, required)
Cover exhaust Cover inlet
Cover VBV Cover exhaust
Cover VBV
Oil wet bearings every 30 days
(BRAYCO 599, or equivalent,
required)
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Table 6-2 LM6000 PC and Major Component Weight and Center of Gravity
Approximate Center of
Weight Gravity Engine Station
Item Component lb. (kg) in. (m)
- Engine, Complete with Fuel System 16,660 (7557) 232.9 (5.9)
1. VIGV Module (see Note) 580 (263) 145 (3.7)
2. LPC Module 2700 (1225) 159 (4.0)
3. Front Frame Assembly 2150 (975) 190 (4.8)
4. Air Collector 1000 (454) 190 (4.8)
5. Accessory Gearbox 580 (263) 190 (4.8)
6. Midshaft Assembly 280 (127) 232 (5.9)
7. Core Module (does not include item 8) 2500 (1134) 235 (6.0)
8. HPT Module 800 (363) 267 (6.8)
9. LPT Module (less items 10, 11, 12, and 13) 6400 (2903) 297 (7.5)
10. Miscellaneous External Attachments 370 (168) 151 (3.8)
11. Fuel System (Manifold, Hoses, and Valves) 370 (168) 240 (6.1)
NOTE An inlet frame weighs 570 pounds (259 kg) and has a center of gravity at station
145 inches (3.7 m). Fuel system weight is for a dual fuel system. A gas/steam fuel system is
70 pounds (32 kg) heavier and a liquid/water fuel system is 180 pounds (82 kg) lighter. Weights
are for a steel A-286 HPC stages 3-9 spool. Titanium spool is 300 pounds (136 kg) lighter.
Weights exclude starter and clutch.
6-4.4 Engine Power Output Shafts b. The VIGV forward inner flange mates
with either the packager-supplied radial air
The engine is equipped with flanged drive inlet system or the centerbody (bullet
adapters at both the forward and aft ends to nose) supplied with the engine for axial air
accommodate forward or aft drive arrange- inlet system. Refer to the appropriate sec-
ments. The packager-supplied coupling shaft, tion of the packager's manual for details.
which mates with the engine drive adapter,
incorporates a close-tolerance rabbet-fit and c. For installations with an axial inlet, a
must be dynamically balanced and aligned in packager-supplied air inlet bellmouth is
accordance with packager-supplied instruc- independently supported at the forward
tions. This must be done during initial installa- enclosure bulkhead. The flowpath between
tion and subsequent to any removal or the bellmouth and the engine is formed by
replacement of the engine. a liner following the contour of the bell-
mouth. Any gap outboard of this liner
6-4.5 Flange Interfaces must be sealed to prevent inflow of ambi-
ent air.
a. The VIGV case forward outer flange
mates with the outer flowpath structure of
the packager's inlet system.
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Figure 6-3 Engine Mount Diagram
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d. The aft or exhaust interface flanges are on b. After 1000 hours of operation in which no
the turbine rear frame. The outer and inner debris is found in the inlet plenum or cap-
flanges mate with the packager's exhaust tured by the screen, the operator/user may
outer and inner flowpath diffuser. These find it advantageous to replace the 800-
joints normally incorporate a piston ring micrometer screen with a coarser 1200-
assembly to accommodate thermal growth micrometer mesh to reduce the rate of
of the engine. screen fouling. A 55-60 porosity rating is
recommended.
6-3
6-4
6-5 Auxiliary Systems 6-5
6-5.1.1 Air Filtration
Provision is made in the packager's design to
accommodate the following conditions and a. The air entering the inlet of the engine
auxiliary requirements. must meet the following conditions:
6-5.1 Inlet System • 95 percent of the time: must not con-
tain solid particles exceeding 0.004
There are two basic inlet system designs for grains/1,000 ft3 (0.0097 grams/1,000
the engine. A radial inlet is required for a front m3)
drive application and may be used with a rear • 5 percent of the time: must not contain
drive configuration. An axial inlet with a bell- solid particles exceeding 0.04 grains/
mouth and centerbody can only be used with a 1,000 ft3 (0.097 grams/1,000 m3)
rear drive configuration. These two arrange-
ments are shown schematically in figure 6-4,
6-5, and 6-6. b. For operation in marine environments,
CAUTION Ensure the clearance between sodium entering the engine should not
the inlet baffles and the VIGV forward flange exceed 0.00045 ppm average or 0.003
is correct or engine damage could result. ppm maximum. These limits apply to both
Refer to the packager's manual for the air entering the engine and to the cooling
proper clearance dimension. air supply. Depending on fuel
characteristics, inlet air contamination
a. The air inlet system provides for the fol- may require restriction below the levels
lowing: stated above. The combination of
entrained sodium entering the engine
• Clean airflow with minimum pressure through inlet air and fuel contamination
loss in order to minimize any effect on must not exceed 0.2 ppm. See
engine performance. Appendix A.
• An inlet screen forward of the VIGV c. The maximum allowable liquid water con-
and LPC to protect compressor flow- tent in the inlet air is 0.5 percent of the
path components from ingesting for- inlet airflow weight (approximately
eign objects. 350 lb/s [159 kg/s]) at air inlet tempera-
• Mounting of a nylon mesh screen (on tures of 42°F (5.6°C) and above. At tem-
the inlet described above) with open- peratures below 42°F (5.6°C), no liquid
ings that do not exceed 800 microme- water content is allowed due to the poten-
ters and a porosity rating of 55-60 tial for icing.
percent open area.
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Figure 6-4 Radial Inlet Duct Interface
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Figure 6-5 Radial Inlet Duct
6-5.1.2 Anti-Icing An alternate method, which eliminates the
need for a humidity sensor, is to heat the inlet
Under certain conditions, as a function of tem- air 10°F (5.6°C) above ambient temperature
perature and humidity, ice can form at the when ambient temperatures are less than 30°F
engine inlet, be ingested into the flow path, (-1.1°C) and to heat the inlet air to 40°F
and cause foreign object damage (FOD). The (4.4°C) when ambient temperatures are
engine is not equipped with an integral anti- between 30°F and 40°F (-1.1°C and 4.4°C).
icing protection system. GE does recommend, No heating is required for ambient tempera-
however, that such a system be installed and tures above 40°F (4.4°C).
operational for any installation operating in a
6-6
climate where the temperature can fall below 6-5.2 Exhaust System
40°F (4.4°C).
To recover the greatest amount of exhaust
The anti-icing system, whether installed by the
total pressure, a rear diffuser is used to decel-
operator/user or the packager, must ensure that
erate the flow. Figure 6-8 shows a radial dif-
the humidity and temperature measured at the
fuser arrangement. An axial design diffuser is
engine inlet are within the limits shown in
shown in figure 6-9. The inner and outer dif-
figure 6-7.
fuser walls connect to the turbine rear frame
through piston ring seals. Figure 6-10 shows
the diffuser/piston ring interface.
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Figure 6-6 Axial Inlet Duct Interface
6-5.3 Secondary Cooling Air 6-6 Support Services
During operation, heat is released by the The following packager/operator-supplied
engine through radiation and convection from support services are required for operation of
hot surfaces, by hot air leakage, and by vent the engine as part of the overall system.
air. In order to maintain enclosure and engine
component temperatures at acceptable limits, • Unloading and installation of all equip-
secondary cooling air must be provided. ment
Secondary cooling air must be filtered so that • Fuel supply to the engine in accordance
solid material in the air does not exceed with the applicable GE specification
0.2 grains per 1,000 ft3 (0.013 grams per
28.32 m3) of air and the size and density dis- • Verification of site conditions, including
tribution should be such that no more than inlet air quality and fuel quality
5 percent (by weight) of the solid particles are
10 micrometers or greater in size. Air contain- • Lubrication system external to the engine
ing salts, or other corrosive elements, have a
• Fuel metering and control systems; engine
harmful effect on the engine and must be fil-
speed-governing and protection systems
tered or washed from secondary cooling air
circuits.
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Figure 6-7 Temperature/Humidity Limits
• Engine base, mounting structure, sound • Electric power supply
enclosure, inlet system, exhaust system,
and front or rear flexible drive coupling • Control and instrument panel, including all
interconnecting wiring and piping
• Fire detection and protection system
• Air, natural gas, or hydraulic supply to the
• Water supply and control system for starter and discharge ducting or piping
water-washing of the engine from the starter
• Engine cooling and post-shutdown frame • Personnel safety protection features
cooling
• Condition-monitoring systems
• Anti-icing system (as applicable) 6-7
6-8
6-9
• Vent and drain systems
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Figure 6-8 Radial Exhaust Diffuser
6-7 Maintenance Level 2: Any maintenance activity associated
with the interior or flowpath of the engine.
The engine is designed and mounted in the This includes removal and replacement of
enclosure with consideration of site mainte- complete module assemblies, such as, the
nance requirements. Maintenance activity on VIGV, LPC, AGB, High Pressure Compressor
the engine falls into the three following cate- (HPT), and other components.
gories:
Depot: Any activity that requires detailed
Level 1: Any maintenance activity associated teardown and/or test verification that can only
with the exterior of the engine, up to, and be accomplished in a designated repair
including, removal and reinstallation of the facility.
complete engine assembly.
All level 1 and 2 maintenance activities are
detailed in individual work packages con-
tained in Volume II of this manual.
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Figure 6-9 Axial Exhaust Diffuser
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Figure 6-10 Diffuser/Piston Ring Interface
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3 CHAPTER 7
Installation and Startup
7-1 Purpose and Scope 7-3 Installation
This chapter covers the installation procedure If not already installed in the package, the
references, pre-startup inspections, and verifi- engine should be installed according to the
cation tests for the engine following initial packager's requirements and specifications.
installation and/or subsequent removal, and For specific details on installation, refer to
replacement or maintenance of the engine, WP 3010 00 and WP 3014 00 and to the pack-
major components, or supporting systems. ager's manual.
7-2 General 7-4 Pre-Startup Inspections
The following procedures are intended to pro- The engine and package should undergo a
vide operating personnel with the information thorough pre-startup inspection, during instal-
required to operate the engine safely and reli- lation or after maintenance, to ensure a trou-
ably. Some of the information contained in ble-free transition from installation to full
this chapter is also provided, in whole or part, operation. This inspection will help to detect
in other chapters. Redundancy is used to pro- potential installation problems. Record the
vide as much specific detail as required. Some results of the prestartup inspection checklists
material is generic in nature and may not provided in Figure 7-1 through Figure 7-4 to
apply to a specific engine model or installa- ensure a complete prestart inspection was per-
tion. It is also likely that the information may formed. The following inspections should be
not provide for every variation in installation performed during installation of the engine in
equipment, or contingency to be found in con- the enclosure:
junction with engine operation. Customer's
should comply with that which is applicable to a. Perform an external inspection per
their model or configuration. Additional infor- WP 4012 00. Ensure that all air tube, hose,
mation can be provided by the packager or by and electrical harness and cable connec-
GE. tions are tight and that no binding or chaf-
ing is evident. Shake all air tubes and hard
The material provided in Chapter 8 on Safety leads to ensure that they are secure and
Equipment and Engine Protection should be clamps are tight. Ensure that gas turbine
previewed prior to proceeding. components do not contact package com-
ponents (at noninterface locations). Failure
to do so will result in accelerated compo-
nent wear.
b. Ensure all electrical harnesses, cables, and
leads are properly routed and connected.
Verify interfaces are correct.
7-1
7-2
7-3
7-4
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Figure 7-3 Distillate Fuel Systems (Including D/F Systems) Checklist (Sheet 1 of 7)
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Figure 7-3 Distillate Fuel Systems (Including D/F Systems) Checklist (Sheet 2 of 7)
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Figure 7-3 Distillate Fuel Systems (Including D/F Systems) Checklist (Sheet 3 of 7)
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Figure 7-3 Distillate Fuel Systems (Including D/F Systems) Checklist (Sheet 4 of 7)
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Figure 7-3 Distillate Fuel Systems (Including D/F Systems) Checklist (Sheet 5 of 7)
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Figure 7-3 Distillate Fuel Systems (Including D/F Systems) Checklist (Sheet 6 of 7)
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Figure 7-3 Distillate Fuel Systems (Including D/F Systems) Checklist (Sheet 7 of 7)
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Figure 7-4 Gaseous Fuel Systems Checklist (Sheet 1 of 3)
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Figure 7-4 Gaseous Fuel Systems Checklist (Sheet 2 of 3)
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Figure 7-4 Gaseous Fuel Systems Checklist (Sheet 3 of 3)
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c. Inspect the engine inlet area per ply system (reference Chapter 8, Lube
WP 4010 00. Thoroughly clean inlet ple- Oil).
num of dirt and foreign objects. Vacuum
and/or wash the area as necessary. No fas- h. Inspect lube and scavenge pump screens,
teners, loose or trapped material, or weld and remove and clean or replace all system
slag/spatter is allowed. Weld splatter that filters to avoid engine contamination. GE
is attached to or trapped behind the inlet also recommends that an oil sample be
plenum perforated plate must be com- taken per WP 4016 00 to verify oil quality,
pletely removed. Remove weld splatter by and that it is free of contamination.
mechanical means, as required. Failure to
remove all loose or weakly constrained i. Ensure that the air/oil separator system
material will likely result in gas turbine and all vents and drains are free and clear.
damage from material ingested through Remove any restrictions, and clean as
the gas turbine inlet. required.
d. Inspect bleed air ducting to ensure the sys- j. Ensure that the gas turbine fuel and water/
tem is free of blockage and the exhaust steam meets GE specification require-
area is clear as specified in Chapter 8, ments. Based on experience, GE strongly
Equipment Protection. Inspect bleed air urges customers to regularly check fuel
ducting including potential traps for samples, particularly given the damaging
debris. No weld slag/splatter or loose effects of noncompliant fuel on gas turbine
material is allowed. Clean using mechani- components. GE also recommends that
cal means as required. particular attention be given to the Fuel
Forwarding Recommendations provided
e. Perform an exhaust system inspection per in the Liquid Fuel Specification and
WP 4013 00. Ensure that exhaust compo- Chapter 5 to assure that fuel remains con-
nents are aligned with the turbine rear tinuously free of contamination.
frame, that there are no obstructions, and
that the flowpath is smooth. k. Calibrate thrust balance valves.
f. Ensure that lube, fuel, water/steam, and l. Verify packager fuel and hydraulic system
purge systems are properly routed and for correct installation. Reference the
connected. Assure that gas and steam man- appropriate packager's manual.
ifolds are aligned properly per
m. Verify high pressure compressor (HPC)
WP 3015 00.
discharge temperature (T3) and low pres-
g. Ensure that the lube system is sure turbine (LPT) inlet temperature (T48)
properly serviced. Engine oil should be thermocouples. Confirm proper thermo-
MIL-PRF-23699 per the requirements of couple wiring. All gas turbine thermocou-
Chapter 5. GE recommends that the lube ples are type K and can be verified by wire
system be flushed prior to gas turbine color. Input the proper type K voltage at
installation for a new plant, prior to instal- the gas turbine electrical panel for T3 and
lation of engine or module replacement T48 and readout on the engine control to
due to lube or sump component failure, or confirm proper system setup.
on-site repair of the gas turbine lube sup-
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n. Verify pressure measurement systems. c. Perform an ignition system functional
Calibrate the gas turbine pressure sensors check per WP 4023 00. Verify that proper
and check gas turbine to transducers to igniter is selected by the control.
verify no leaks. Verify proper control wir-
ing by reading out control output during d. Dry motor the engine for 2 minutes per the
calibration. Hook up the sense lines to packager's manual and dry motoring
their proper interfaces per the packager's instructions in Chapters 8 and 12 of this
appropriate manual. Confirm HPC dis- manual. During motoring, check for the
charge static pressure (PS3) and LPT inlet following:
pressure (P48) are not switched. Assure • Oil supply pressure indication
that inlet pressure (P0) is accurately cali-
brated using an absolute pressure refer- • Lube oil leaks
ence. • Unusual noise during coastdown
o. Verify variable-geometry. Calibrate vari- e. Wet motor liquid fueled engines per the
able inlet guide vanes (VIGVs), variable procedure described in the wet/dry motor-
bypass vanes (VBVs), and variable stator ing section of Chapters 8 and 12 of the
vanes (VSVs). Visually verify that vari- manual. It is also recommended that the
able-geometry slews to the proper position liquid fuel circuits of dual-fueled engines
during calibration. be checked for fuel system leaks at this
time.
7-5 Operational Checkout
WARNING When working inside or near
CAUTION If a questionable condition the engine enclosure during operation,
exists, do not attempt to motor or operate the observe the safety precautions described in
engine until a thorough investigation of the Chapter 8.
condition has been made. Do not repeat hot
starts, compressor stalls, load–shedding, or f. Make a start (Chapter 8, Starting and
other problems that initiate emergency shut- Operation) and set power at idle. When the
downs or aborted operation without thorough engine is stabilized at idle, do the follow-
investigation. Failure to do so can result in ing:
undue stress on engine components that may
result in damage or subsequent destructive • Check engine and supply systems for
failure of the engine. leaks.
The initial startup procedures described in this • Check for loose parts, tubing, cabling,
section should be followed after any LM6000 etc.
PC gas turbine installation or internal mainte-
nance. • Observe and record all results.
a. Inspect the enclosure per the packager's g. If any discrepancies are noted, make a nor-
instructions. mal or emergency shutdown, as required,
(Chapter 8, Shutdown Procedures). Other-
b. Perform normal prestart checks wise, proceed to the verification test
(Chapter 8, Starting and Operation). paragraph 7-6, if required.
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h. Correct any discrepancies noted during the f. Inspect for leakage and loose parts and
initial startup. take any corrective action required.
7-6 Verification Test g. Check lube and scavenge pump screens
for evidence of contamination per
If no verification test is specified by the pack- WP 4020 00.
ager, the verification test, described below,
should be performed after the initial startup h. Check inlet/fine mesh screen for any
procedure has been completed. debris per WP 4020 00. If any debris is
found, its source must be identified and
a. Make a start (Chapter 8, Starting and eliminated.
Operation), if required.
i. Water injection rate should be established
b. Slowly advance to full power. If the accel by setting values in the packager control
follows a cold start, it should be at a rate system to meet the site contractual emis-
not to exceed zero to maximum load in sions levels. Emissions measuring equip-
less than 5 minutes (approximately 8 mW/ ment in the gas turbine exhaust (upstream
minute, or less). A ramped (constant rate) of any devices such as catalysts, duct burn-
load increase should be maintained during ers, etc. that affect emissions) will be
the accel. required to establish the proper engine
water-to-fuel ratio when an engine is
c. Stabilize at full power for at least 3 installed or the fuel system, combustor or
minutes, then observe and record the data hot section components, are changed.
specified in Chapter 8, Engine Water injected to achieve NOx emissions
Performance. levels lower than 42 ppm, 15 percent O2,
may impact combustor and/or hot section
d. Reduce power to idle, if required. life. Water injection resulting in emissions
levels lower than 25 ppm NOx, 15 percent
e. Perform a normal shutdown, if required
O2, will significantly impact combustor
(Chapter 8, Shutdown).
and hot section life and are not recom-
mended.
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7 CHAPTER 8
Engine Operation
8-1 Purpose and Scope The outside surfaces of the engine are not
insulated. Adequate precautions should be
This chapter covers general operating taken to prevent personnel from inadvert-
procedures for the LM6000 PC. The ently coming in contact with hot surfaces.
procedures discussed are typical of any
LM6000 PC-powered package but should not The engine is a source of considerable
be considered totally comprehensive for any noise. It will be necessary for personnel
specific installation. Configuration and system working on it, or in its vicinity, to wear
procedures may vary from package to package proper ear protection equipment when the
and with the packager-supplied control engine is operating.
system. Prior to operation of the engine, the
site operators should be thoroughly schooled The LM6000 PC is a high-speed machine.
in both normal and abnormal (emergency) In the remote case of parts failure, the cas-
operation and the control system action/ ing may not contain major compressor or
reaction to these conditions. turbine disk failures. Personnel should not
be permanently stationed in, or near, the
8-2 General plane of the rotating parts.
The following procedures are intended to pro- Rotating parts of the starter operate at a
vide operating personnel with the information very high speed. In the remote case of a
required to operate the engine safely and reli- parts failure, personnel should not be sta-
ably. Some of the information contained in tioned near the starter during start, motor-
this chapter is also provided, in whole or part, ing, or purge cycles.
in other chapters. Redundancy is used to pro-
vide as much specific detail as required. It is The low pressure (LP), high-velocity air-
also possible that the information may not pro- flow created by the compressor in the
vide for every variation in installation, equip- LM6000 PC can draw objects and person-
ment, or contingency to be found in nel into the engine. The use of an inlet
conjunction with engine operation. Additional screen or other protective measure is
information can be provided by the packager mandatory.
or by GE.
In the event that the fire extinguishing sys-
8-3 Safety tem is activated, care must be taken to
ensure that all personnel are clear of the
General safety precautions are defined in enclosure prior to activation. Due to lack
Chapter 1. The following safety consider- of oxygen, failure to comply may result in
ations should be observed by operators and injury or death to personnel remaining
support personnel working on the engine: inside the enclosure.
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Suitable fire protection equipment should 8-3.1 Gas Turbine Maintenance/
be provided for the installation. Carbon Inspection Precautions
dioxide, halides, fog, water, or chemical
fire extinguishing systems may be used. WARNING When entering the gas turbine
Discharge of fine chemical or water mists enclosure, the following requirements shall
directly on engine casings is permissible. be met:
The use of chemical fire extinguishing
media will require the disassembly of the • The gas turbine shall be shut down.
engine for cleaning.
• Module entry during engine operation
is prohibited in general. If entry should
Suitable explosive mixture sensing devices
be required during engine operation,
should be provided to sense any leakage of
contact GE Field Service for a represen-
fuel (both into the enclosure and into the
tative who is trained to enter the module
fuel manifold) and to shut down the engine
under such conditions.
if leakage is present.
• The fire extinguishing system shall be
WARNING When entering the gas turbine made inactive according to the cus-
enclosure, the following requirements shall tomer's procedures.
be met:
• Secondary air to the enclosure shall be
• The gas turbine shall be shut down. shut off, since high secondary airflow
may prevent opening or closing the
• Module entry during engine operation
enclosure door.
is prohibited in general. If entry should
be required during engine operation, • The enclosure door should be kept open.
contact GE Field Service for a represen- If the gas turbine is operating, an
tative who is trained to enter the module observer should be stationed at the
under such conditions. enclosure door and confined space entry
procedures shall be followed.
Personnel entry into the engine enclosure
during operation at engine speeds above • Allow gas turbine to cool down. Avoid
core idle should be prohibited. This prohi- contact with hot parts, and wear ther-
bition should include operation at synchro- mally insulated gloves as necessary.
nous idle. Signs or placards should be
posted at the enclosure access doors and • Ear protection shall be worn if gas tur-
should clearly state the hazardous condi- bine is operating.
tions that exist in the enclosure during
operating above core idle. • Do not remain in the enclosure or in the
plane of rotation of the starter when
starting or motoring the gas turbine.
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• When performing maintenance on elec- shipping, handling, installation, and main-
trical components, avoid shocks and tenance activity. These covers are used to
burns by turning off electrical power to protect the engine from potential foreign
those components, except when power is object damage (FOD) caused by handling and
required to take voltage measurements. objects such as dirt, weld beads, tools, and
rags. Should an object be dropped during
• Lock out all controls and switches, if maintenance it should be found at once to
possible; otherwise, tag electrical preclude having objects inadvertently dropped
switches out of service to prevent inad- into the gas turbine.
vertent activation. Tag the engine oper-
ating controls do not operate to prevent 8-4.1 Inlet Cover
starting during a desired shutdown
condition. The engine is shipped with an inlet cover that
should only be removed when the variable
• The Component Life/Repair Intervals inlet guide vane (VIGV) forward flange is to
section of this chapter provides mainte- be mated with the radial inlet or bellmouth.
nance guidelines for certain compo- This cover should be retained by the operator
nents, based on total equivalent base and installed for engine protection any time
load and peak load hours. For contin- the VIGV flange to inlet or bellmouth connec-
ued safe operation, it is essential that tion is broken.
these guidelines be followed.
8-4.2 Bleed Air Collector Cover
• Do not use engine piping, cables, instru-
mentation leads, or other external hard- The bleed air collector discharge is covered
ware as hand or footholds when during shipment. This cover should not be
performing maintenance activity on the removed until a clean, uncontaminated envi-
engine. These hardware items are not ronment downstream of this flange can be
designed to support loads other than assured.
those associated with engine operation.
Similar to the inlet cover, this cover should
• On models with steam injection systems, also be retained by the operator and installed
the steam piping runs and flanged joints under the following conditions:
are potential sources of hot surfaces and
steam leakage. Personnel entering the • When maintenance activity dictates that
enclosure should be aware of these this connection be broken.
conditions.
• When maintenance activity is performed
8-4 Equipment Protection in the bleed air ducting. In this case, the
cover should be installed and left in place
The engine is provided with covers that until the ductwork has been blown down
protect various operational interfaces during or otherwise cleaned of all debris.
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8-4.3 Exhaust Cover vides the operator with specific requirements
concerning the air, oil, and fuel used during
The engine is shipped with an exhaust cover normal operation. The guidelines are designed
which should be left in place until the engine to ensure that the engine is operating in the
is mated with the exhaust duct. environment, and under conditions, for which
it was designed.
Similar to the inlet and bleed air collector cov-
ers, this cover should also be retained by the 8-5.1 Lubricating Oil
operator and installed any time the engine is
disconnected from the enclosure/ site exhaust Lubricating oil, is used to lubricate bearings,
duct. sumps, and gearboxes. flows at a rate of 10 to
18 gpm. The oil must be temperature-con-
8-4.4 Electrical, Fluid, and System trolled and kept clean per the following
Interface Covers requirements in order to adequately perform
its function.
The engine is shipped with protective covers
over all electrical, fluid, and system interfaces. 8-1
a. Minimum temperature at start is 20°F
These covers are in place to prevent handling (-6.7°C) for type II (MIL-PRF-23699) oil.
damage (threads, pins, etc.) and fluid or sys- Figure 8-1 shows typical gas turbine lube
tem piping contamination. oil supply pressure. Note that typical lube
oil pressure is affected by lube oil supply
A supply of these covers should be maintained
temperature. Figure 8-1 shows pressures
by the operator for use during maintenance
for typical supply temperatures. At the full
activities that require electrical leads, fluid
power settings, typical maximum oil sup-
piping, or system piping to be disconnected.
ply pressures are shown for an oil supply
temperature as low as 100°F (37.7°C). Oil
8-5 Engine Protection
supply pressures outside the bounds of fig-
The LM6000 PC is a reliable, durable engine ure 8-1 may indicate a problem. Refer to
designed to operate in an industrial atmo- Chapter 10, Troubleshooting, for correc-
sphere for extended periods of time. However, tive action.
the operator needs to follow certain basic pro-
b. Minimum allowable temperature for oper-
cedures in order to enhance the engine's opera-
ation at synchronous idle or above is 90°F
tional capability.
(32.2°C).
In other portions of this manual, specifically
c. Mixing of MIL-PRF-23699 oils from dif-
Chapter 5, 6, and 7, information is included on
ferent supply sources should be done by
safety, equipment, protection, records, inlet/
topping off the lube tank rather than com-
enclosure inspections, pre-start checks, and
plete replacement. Reference the lube oil
operations. These topics are all directed at
supplier for additional recommendations.
ensuring that the operating, maintenance, and
Refer to Chapter 5 for additional informa-
support personnel have a source of technical
tion.
information associated with the engine and its
operation as installed in an enclosure. It pro-
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Figure 8-1 Gas Turbine Lube Oil Supply Pressure
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d. Flushing of the off-engine lube oil system NOTE Following this flushing, the system fil-
should be performed prior to connecting ters should be removed and cleaned or
the off-engine lubrication system to the replaced to avoid engine contamination.
LM6000 or any time that particulate con-
tamination is suspected (including lube e. In the event of a failure during site opera-
system maintenance). The flush system tion that involves the engine lube system,
uses an off-engine flush pump and filter to the system should be disconnected,
clean particulate contaminates from the oil drained, and cleaned as described in
system prior to connecting it to an engine. step d. This procedure should be followed
The flush system should consist of a pump whether the engine is removed and
which can produce approximately 30 gpm replaced or repaired on-site.
flow (113.5 lpm). Flow should be filtered
using a 3 micron cleanup filter. f. Engine oil is filtered to 3 micrometers,
absolute.
(1) Inspect the inside of supply oil tank
for contamination. Wipe all tank sur- 8-5.2 Air
faces clean and then install tank cover.
Maximum airflow through the LM6000 PC
(2) Connect a flush cart (see note on engine is approximately 350 lb/sec
figure 8-1) to the lube system supply (159 kg/sec) and is filtered by the inlet system
and return interface connections to meet the following requirements:
(see figure 8-1 for typical system).
• 95 percent of the time: must not contain
Each supply and return may be
solid particles exceeding 0.004 grains/
flushed separately or a manifold
1,000 ft3 (0.0097 grams/1,000 m3)
arrangement can be used to flush all
circuits simultaneously (include stator
• 5 percent of the time: must not contain
and hydraulic pump circuits if appli- solid particles exceeding 0.04 grains/1,000
cable). ft3 (0.097 grams/1,000 m3)
(3) Start flush pump and monitor system
• When operating in a marine environment,
cleanliness. Oil should be sampled sodium (from air or water) entering the
periodically. engine should not exceed 0.00045 lb/sec
(0.000204 kg/min) average, or 0.003 lb/
(4) Actual required flush time will vary
sec (0.0014 kg/min), maximum.
depending on the initial system con-
tamination level and the actual system • The maximum allowable liquid water con-
volume. It is expected that a minimum tent in the inlet air is 0.5 percent of the
of 8 hours of continuous flushing will inlet airflow weight at inlet air tempera-
be required to clean-up a typical facil- tures of 42°F (5.6°C) and above. Below
ity oil system. 42°F (5.6°C), no liquid water content is
allowed.
(5) When oil sample meets cleanliness
standards outlined in WP 4016 00, the
engine may be installed.
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8-5.3 Fuel c. Reference Appendix A2 for additional liq-
uid fuel requirements.
The engine can operate on either gas or liquid
fuel and the following general guidelines 8-5.4 Water
apply.
Water injection rate should be established by
8-5.3.1 Gas Fuel setting values in the packager control system
to meet the site contractual emissions levels.
Gas fuel should be what is known in industry Emissions measuring equipment in the gas
as dry gas. That is, the gasoline vapor in 1,000 turbine exhaust (upstream of any devices such
ft3 of gas at standard conditions (60°F and 30 as catalysts, duct burners, etc. that affect emis-
in. Hg abs) should not exceed 0.1 gallon of sions) will be required to establish the proper
liquid. engine water-to-fuel ratio when an engine is
installed or the fuel system, combustor or hot
Liquid hydrocarbons in gas fuel can cause section components, are changed. Water
surges in operation or engine damage. There- injected to achieve NOx emissions levels
fore, gas fuel mixtures must be maintained at lower than 42 ppm, 15 percent O2, may impact
temperatures well above their dewpoint at the combustor and/or hot section life. Water injec-
engine fuel manifold inlet. tion resulting in emissions levels lower than
25 ppm NOx, 15 percent O2, will significantly
Reference Appendix A1 for additional gas
impact combustor and hot section life and are
fuel requirements. not recommended.
8-5.3.2 Liquid Fuel
Water used for NOx suppression shall contain
Liquid fuel shall consist of hydrocarbon com- no particles larger than 20 micrometers abso-
pounds only and must be compatible between lute. Total matter, lb/min, shall not exceed a
brands or batches. maximum of 5.0 Additionally, pH shall be
between 6.0 and 8.0 and conductivity at 77°F
a. Viscosity of liquid fuel shall be a mini- (24.9°C), between 0.5 and 1.0 micro-mhos/cm
mum of 0.5 centistrokes and shall be 6.0 (measured when the water is free of carbon
centistrokes for starting and a maximum of dioxide).
12.0 centistrokes for operation.
Water used for Sprint® water injection, on
b. In installations where liquid fuel is used engines so equipped, shall meet the same
without benefit of water for NOx suppres- requirements previously described for NOx
sion, the liquid fuel shall be heated to 35°F suppression.
(1.6°C). This requirement applies any time
the gas turbine operates on liquid fuel for a Reference Appendix A3 for additional
continuous period of time greater than 2 requirements for water used for NOx suppres-
hours. sion or SPRINT® injection.
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8-5.5 Steam and/or running time. It is recommended that,
as a suggested minimum, site operators should
Steam used for NOx suppression shall contain record the following:
no particles larger than 250 micrometers.
Total solids allowable depends on the steam- • Time of all starts and shutdowns
to-fuel ratio on which the engine operates.
This will vary from site to site. Additionally, • Total time for engine and site
its total conductivity at 77°F (24.9°C),
between 0.5 and 1.0 for 95 percent or more of • Reading of all engine instrument record-
the operating time and is limited to a maxi- ings, taken twice daily at the set-load point
mum of 2.0 for 5 percent or less of the operat-
• All changes of engine speed and load
ing time.
• Brief statement of action taken in response
NOTE
to alarms or emergencies
• All steam system piping, valves, purge
lines, drains, and blowoff lines must be • Any system modifications, adjustments,
blown down and cleaned before final con- or parts removal/replacement
nection to the engine is made.
• Preventive or corrective maintenance
• Flange and gaskets must be designed to activity
prevent deteriorated gasket material from
• Lease pool, running time, change dates
entering the steam system and the engine.
• It is recommended that 250 micrometer 8-7 Inlet/Enclosure Inspection
strainers be installed upstream of the
Ensure that the inlet and enclosure have been
steam control skid.
inspected and cleaned in accordance with
Steam must have a minimum superheat of instructions in the packager's manual. Refer to
50°F (9.9°C) at the engine manifold inlet. Chapter 7 of this volume and Volume II, work
Preheat and drain provisions must be made to packages 4010 00,4012 00, and 4013 00.
heat the supply lines, and to drain off any
condensate in the lines just prior to steam 8-8 Prestart Checks
injection.
Consult the packager's manual for mandatory
To prevent recirculation and ignition of natu- prestart procedures specifying that the pack-
ral gas in the steam manifold, steam must be ager-furnished lube supply subsystem is acti-
initiated by 10 MW. If steam is not available, vated and operational.
the steam manifold should be disconnected
Prior to any motoring or start sequence, GE
and the fuel nozzle steam connections capped.
suggests the following checks as a minimum:
Failure to follow this procedure will result in
steam hose burning. • All maintenance requirements or discrep-
ancies cleared and signed off
8-6 Records and Running Log
• Fuel shutoff valves closed
A log should be kept of all engine operation
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• Water shutoff valves closed • VIGVs, variable bypass vanes (VBVs),
and variable stator vanes (VSVs) on
• Fuel boost pump on schedule
• Water supply pump: per packager's opera- • Fuel drain valve closed (if applicable)
tional procedures
• Flameout detection circuit OK
• Steam supply pump: per packager's opera-
tional procedures • Flame detection cooling air on
• Lube tank level full • Secondary fuel manifold purge valve
closed
• Lube supply valves open
• Gas vent valves set for gas startup
• Water-wash solenoid (if applicable)
deenergized Although not required as part of normal start-
ing procedures, wet and/or dry motoring must
• All switches and interlocks set for proper be used following engine installation or any
sequence to allow motoring fuel system maintenance to check the engine
prior to start. Wet motoring (liquid fuel only)
• Fuel valve at start position is performed with the fuel metering valve at
minimum position and the fuel shutoff valves
• High pressure compressor (HPC) rotor open. Dry motoring is performed with the fuel
speed (XN25) and low pressure turbine shutoff valves closed.
(LPT) rotor speed (XNSD) governor refer-
ences at lowest point
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8-9 Motoring Procedures b. With the fuel shutoff valves closed, acti-
vate the motoring or start sequence and
8-9.1 Dry Motoring allow the engine to motor to maximum
motoring speed for 30 seconds. Observe
Any dry motoring check should be made with and record the following:
the ignition system deenergized.
• Engine high pressure rotor speed
CAUTION Be certain that checklists have
been established for packager-furnished • Starter air or hydraulic inlet pressure
equipment. Consult the packager's manual
for mandatory prestart procedures and make • Inlet air temperature
certain that the packager-furnished lube sup-
ply subsystem is activated and operational • Lube supply pressure
prior to any motoring or start sequence.
c. After 30 seconds, deenergize the starter.
a. Check all switches and interlocks for
proper motoring settings.
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8-9.2 Wet Motoring (Liquid Fuel Only) d. Deenergize the starter.
Any wet-motoring check should be made with 8-10 Starting and Operation
the igniter system deenergized.
8-10.1 Normal Starting Sequence
CAUTION
CAUTION It is critical that the cold restart
• Excessive wet motoring can result in sat- procedure be followed; otherwise, major
uration of the TRF insulation blanket engine damage can result.
with fuel.
a. Ensure that all prestart checks have been
• Be certain that checklists have been completed.
established for packager-furnished
equipment. Consult the packager's man- b. Open the starter shutoff valve or initiate
ual for mandatory prestart procedures the start sequence. The following should
and make certain that the packager-fur- occur:
nished lube supply subsystem is activated
and operational prior to any motoring or • The engine will begin to rotate for a
start sequence. Failure to comply can predetermined period to purge the
result in engine failure. exhaust system.
a. Check all switches and interlocks for • The starter will rollback the core speed
proper motoring settings. to approximately 1,700 rpm or main-
tain the core speed at approximately
b. With the fuel shutoff valves closed, acti- 2,400 rpm (recommended), depending
vate the motoring or start sequence and on packager setting.
allow the engine to motor to maximum
motoring speed for 30 seconds. At maxi- • The ignition will be energized at
mum motoring speed, open the fuel shut- approximately 1,200 rpm for liquid
off valves. Observe and record the fuel and 1,700 rpm for gas fuel.
following:
• The fuel shutoff valves will open.
• Engine high pressure rotor speed
• Lightoff should occur in approxi-
• Starter air or hydraulic inlet pressure mately 10-12 seconds.
• Inlet air temperature • The engine will accelerate to core idle
(starter-assisted to 4,600 rpm, where
• Lube supply pressure starter-cutout occurs).
• Fuel manifold pressure • In power generation applications only,
after a brief pause of no more than 1
c. Close fuel shutoff and continue motoring minute at core idle, during which rota-
for 5 minutes to purge the enclosure/ tion of the low pressure (LP) system
engine fuel system of fuel. If an engine must be indicated, the engine will con-
start is to be made, wait a minimum of 2 tinue to accelerate to synchronous idle.
minutes before initiating the start cycle.
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• Finish 5 minute warmup prior to load- c. If a hot start occurs, the startup procedure
ing (5 minutes total time at core and should not be repeated without investigat-
synchronous idle speed). ing the cause of the hot start. For trouble-
shooting procedures, refer to Chapter 10.
• Maintain a constant rate of load
increase during acceleration (8 mW/ 8-10.2 Special Operating
minute). Stepped accel rate should be Requirements
avoided. If the packager-supplied con-
trol requires a stepped accel rate, the The information in the following paragraphs is
rate shall not exceed specified limits. presented as generic information only. Refer
to the packager's manual for specific control
NOTE Stepped accel rate values will be pro- system sequencing modes and site operation
vided in a later issue of this manual. information.
c. Record the levels for inlet temperature 8-10.2.1 Dual-Fuel Requirements
(T2), the compressor rear frame (CRF) and
turbine rear frame (TRF) accelerometers, • Dual-fuel system startups must be made
and the operating parameters designated on one fuel only (liquid or gas fuel only).
by a double asterisk (**) in table 8-1. If all Single-fuel operation is also required for
parameters are normal, engine operation to all engine speeds below no-load synchro-
load may continue. If engine parameters nous speed.
are outside the normal operating limits
shown in table 8-2, troubleshoot and cor- CAUTION Failure to provide necessary
rect the problem per Chapter 10 before purge of fuel system components could result
continuing. in fuel system hardware failure from back-
flow of combustion products.
d. A typical power generation start-to-load
sequence is shown in figure 8-2. Upon • When operating a dual-fuel system on gas
reaching the desired load condition, record fuel, the liquid manifolds must be purged.
the data indicated in paragraph 8-14. The use of gas fuel from the metered gas
supply to the engine is recommended.
8-10.1.1 Hot Starts
• When operating a dual-fuel system on liq-
a. Hot starts are normally the result of insuf- uid fuel, the gas manifold must be purged
ficient starter power, excess starting fuel to prevent coke deposits in the gas nozzles
flow, excessively high acceleration fuel and feeder tubes. The use of compressor
flow rate, or open VSVs. discharge pressure (CDP) bleed air is
recommended.
8-2
b. Starts indicating a T48 value in excess of
1,300°F (704.4°C) are considered to be hot • For startups, fuel transfer from gas to liq-
starts. Normal starts are 1,000° to 1,200°F uid or liquid to gas should be made only
(537.7° to 648.8°C). after XN25 has reached synchronous idle
or 8,400 rpm.
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Table 8-1 Typical Operating Levels
Base Load
Generator Efficiency 98%, Inlet Loss = 4”H2O; Exhaust Loss 10”H2O; 25 PPM NOx
Maximum Base Maximum
Synchronous Maximum Power Operating
Parameter Core Idle Idle Base Power * SPRINT® * Limit
MW 0 0 41.5-43.3 48-52 N/A
WF, (Fuel Flow), lb/hr 1,350-1,450 4,000-4,200 17,000-19,000 17,000-22,000 21,800
(kg/hr) (612-657) (1,814-1,905) (7,711-8,618) (7,727-10,000) (9,888)
T2 (Inlet Temperature), F 59 59 59 59
(C) (15) (15) (15) (15) N/A
P0 (Ambient Inlet Pressure), psia 14.6 14.4 14.6 14.7
(kPa) (101) (99) (101) (101.3) N/A
T25 (HPC Inlet Temperature), F 80 to 100 180 to 200 210 to 230 198-218
(C) (27 to 38) (82 to 93) (99 to 110) (92-103) N/A
XN25 (HPC rpm) 6,400-6,700 8,400-8,700 10,300-10,500 10,300-10,553 10,700
XN2 (LPC rpm) 1,650-1,800 3,600 3,600 3,600 3,780
XNSD (LPT rpm) 1,650-1,800 3,600 3,600 3,600 3,780
PS3 (HPC Discharge Pressure), 50-57 130-143 390-440 390-455 442
psia (kPa)** (345-393) (896-986) (2,689-3,034) (2,689-3,137) (3,047)
T3 (HPC Discharge Temp), F 360 to 400 650 to 750 990 to 1,008 990-1,001 1,008
(C) ** (182 to 204) (343 to 399) (532 to 542) (532-538) (542)
P48 (LPT Inlet Pressure), psia 22-26 37-41 95-105 95-111
(kPa) (152-179) (255-283) (655-724) (655-765) N/A
T48 (LPT Inlet Temp) F 725 to 825 950 to 1,050 1,540 to 1,600 1,540-1,579 1,600
(C) ** (385 to 441) (510 to 566) (838 to 871) (838-859) (871)
PTB (Thrust Balance Pressure), 16-20 34-38 95-105 95-111
psia (kPa) ** (110-138) (234-262) (655-724) (655-765) N/A
Lube System Oil Supply 28-40 45-58 63-75 63-75 15
Pressure, psig (kPa) (193-276) (310-400) (434-517) (434-517) (103) Min
Lube System Oil Supply Temp, 140 to 160 140 to 160 140 to 160 140-164 170
F (C) (60 to 71) (60 to 71) (60 to 71) (60-73) (77)
Lube Scavenge Pressure, psig 17-21 18-22 18-23 18-23 100
(kPa) (117-145) (124-152) (124-159) (124-159) (689)
Lube Scavenge Temp 150 to 190 165 to 205 240 to 270 240-270 310
(A/TGB-Scav), F (C) (66 to 88) (74 to 96) (116 to 132) (116-132) (154)
Lube Scavenge Temp 160 to 210 210 to 235 250 to 290 250-290 330
(B-Scav), F (C) (71 to 99) (99 to 113) (121 to 143) (121-143) (165)
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Table 8-1 Typical Operating Levels
Base Load
Generator Efficiency 98%, Inlet Loss = 4”H2O; Exhaust Loss 10”H2O; 25 PPM NOx (Continued)
Maximum Base Maximum
Synchronous Maximum Power Operating
Parameter Core Idle Idle Base Power * SPRINT® * Limit
Lube Scavenge Temp 190 to 225 220 to 255 290 to 320 290-320 340
(C-Scav), F (C) (88 to 107) (104 to 124) (143 to 160) (143-160) (171)
Lube Scavenge Temp 150 to 200 160 to 220 230 to 290 230-290 315
(D-Scav), F (C) (66 to 93) (71 to 104) (110 to 143) (110-143) (157)
Lube Scavenge Temp 150 to 210 160 to 230 230 to 290 230-290 315
(E-Scav), F (C) (66 to 99) (71 to 110) (110 to 143) (110-143) (157)
Lube Scavenge Temp 160 to 210 200 to240 220 to 260 220-260 340
(TGB-Scav), F (C) (71 to 99) (93 to 116) (104 to 127) (104-127) (171)
VIGV Position (percent of stroke) 27-29 27-29 80-93 90-93 102
VSV Position (percent of stroke) 23-25 40-42 80-93 83-96 102
VBV Position (percent of stroke) 98-102 83-85 0-3 0-3 102
*Typical base loaded water-to-fuel ratio = 0.9 to achieve 25 ppm NOx
** Record all sensors.
Table 8-2 Limits and Operating Requirements
Event/Item Max Limits/Requirements
Max Time Allowed for Ignition XN25 > 1,200 rpm at t ≥ 20 sec (liquid fuel)
ΞN25 > 1,700 rpm at t ≥ 20 sec (gas fuel)
Max Time to Reach Starter Cutout XN25 > 4,600 rpm at t ≥ 90 sec
Max Time to Reach Core Idle XN25 ≥ 6,050 rpm and XN25R ≥ 6,400 rpm at t ≥ 120 sec
LP Rotor Vibrations • 1.40 in/sec (3.6 cm/sec) peak at
XN2 Rotor < 3,000 or
XN2 Rotor ≥ 3,590 or
XN25 Sel ≥ XN25 Max
or
• 1.75 in/sec (4.5 cm/sec) peak at
3,000 ≤ XN2 Rotor < 3,590 and XN25 Sel < XN25 Max
HP Rotor Vibrations 2.0 in/sec (5.1 cm/sec)
Fuel Supply Temperature (Gas) < Tsv +20°F (11°C) min; > 300°F (149°C)
Fuel Manifold Temperature > 400°F (204°C); Primary and Secondary
Steam Temperature (Fuel Nozzle) Superheat < 50°F (10°C) or > 1,000°F (538°C) at Manifold
Steam Permissive > 8,000 shp (5,966 kW)
8-14 Change 6
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Table 8-2 Limits and Operating Requirements(Continued)
Event/Item Max Limits/Requirements
Water Manifold Temp > 450°F (232°C)
Steam Pressure > 700 psia (4,827 kPa)
Air Inlet Screen Differential Pressure Pi +1.0 in. H2O (0.249 kPa)
Wideband Rotor Vibrations < 3.00 in/sec (7.6 cm/sec)
Figure 8-2 Typical LM6000 PC Gas Turbine Start-to-Load Time Sequence
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• When transferring from gas to liquid at flow rate is gradually increased to meet the
normal operating power, the LM6000 PC schedule for the particular fuel being used.
should be powered down to reduce T3 to For shutdown, water is shut off prior to
750°F (398.8°C) or less. This reduces the fuel transfer.
possibility of autoignition in the gas sys-
tem. When transferring from liquid fuel • Prior to water flow initiation, it is recom-
back to gas fuel, the LM6000 PC should mended that operation at a stabilized,
be powered down to reduce the air temper- steady-state condition first be achieved.
ature to less than 750°F (398.8°C) before Water should not be introduced below core
introducing natural gas into the manifold idle speed.
containing hot air. If a heat exchanger is • Water injection rate should be established
present in the line to maintain the purge by setting values in the packager control
line air temperature below 750°F system to meet the site contractual emis-
(398.8°C) at high power steady state con- sions levels. Emissions measuring equip-
ditions, transfers may be made at any ment in the gas turbine exhaust will be
power. required to establish the proper engine
8-10.2.2 Fuel/Water Injection water-to-fuel ratio when an engine is
Requirements installed or the fuel system, combustor or
hot section components, are changed.
• Liquid fuel operation will normally Water injected to achieve NOx emissions
require a higher water flow and water levels lower than 42 ppm, 15 percent O2,
pressure than gas fuel operation in order to may impact combustor and/or hot section
meet NOx suppression requirements. life. Water injection resulting in emissions
levels lower than 25 ppm NOx, 15 percent
• For gas fueled systems configured for O2, will significantly impact combustor
water injection for NOx suppression, and hot section life and are not recom-
including dual fuel systems, there is no mended.
requirement to initiate water at a particular
power level. The gas turbine can be oper- 8-10.2.3 High Pressure Steam Injection
ated to base load without water injection. Requirements
• Gas turbines equipped with dual-fuel sys- a. Special sequencing is provided for initia-
tems are designed to operate on 100 per- tion and termination of steam injection on
cent natural gas with water injection, 100 models with steam injection for NOx sup-
percent liquid fuel with water injection, or pression. The sequencing ensures that
on combinations of the two fuels with steam is superheated before being intro-
water injection with no limit on natural duced into the engine, that any condensate
gas-to-liquid fuel ratios, except as specifi- is removed from the lines prior to steam
cally noted. injection, and that appropriate drains are
opened during shutdown conditions. For
• Prior to fuel transfer after starting, the additional information, refer to the pack-
water injection flow is adjusted to a mini- ager's manual.
mum setting. Following transfer, the water
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b. To prevent recirculation and ignition of steam preheat valve is opened to pre-
natural gas in the steam manifold, steam heat fuel nozzle steam injection pip-
must be initiated by 10 MW. If steam is ing. The fuel nozzle steam metering
not available, the steam manifold should valve downstream line is preheated by
be disconnected and the fuel nozzle steam CDP bleed airflow through the CDP/
connections capped. Failure to follow this fuel nozzle preheat pressurization line
procedure will result in steam hose check valve.
burning.
(5) If the engine is operating with fuel
c. Typical steam system valve operating con- nozzle steam injection, the fuel nozzle
ditions are described below. injection preheat valve is closed when
steam temperature sensors and pres-
(1) If the engine is not operating, all sure sensors indicate that minimum
valves remain closed except the power level has been reached and that
water/steam purge valve and the fuel a minimum of 50°F (10°C) superheat
nozzle manifold drain bleed valve. has been achieved upstream of the
The water/steam purge valve allows fuel nozzle steam metering valve and
steam/water leakage from the main at the manifold inlet. The fuel nozzle
shutoff valve to escape from piping steam metering valve is then opened
without building up pressure. The fuel within 30 seconds at a rate not to
nozzle manifold drain bleed valve exceed 250 lb/hr conversion per sec-
prevents condensate from collecting ond and increased to the control
in the fuel nozzle steam manifold. regime (8,000 lb/hr [3628.8 kg/hr]
steam flow minimum). The fuel noz-
(2) If the engine is operating with no zle manifold drain bleed valve is
steam injection, the fuel nozzle opened to drain accumulated water.
manifold drain bleed valve is closed The CDP/fuel nozzle preheat pressur-
to keep the manifold properly ization line check valve will close due
pressurized. to reversed ΔP.
(3) If the engine is operating with water 8-10.2.4 SPRINT® Injection
purge prior to preheating, the main Requirements
shutoff valve is opened with the
water/steam purge valve opened to LM6000PC model engines equipped with
purge any water accumulation ahead SPRINT® include provision to inject a very
of the main shutoff valve. The purge fine water mist in the LPC discharge flow, cre-
is continued until temperature indi- ating an evaporative, intercooling effect and
cates that saturated steam is flowing. enabling higher engine output than would oth-
erwise be achieved with a standard
(4) If the engine is operating with fuel LM6000PC. SPRINT® can be used in con-
nozzle steam system preheating, the junction with any fuel type and any NOx sup-
water/steam purge valve and the fuel pression configuration.
nozzle manifold drain bleed valve are
closed. The fuel nozzle upstream
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The percent increase in power due to greater power. The LP speed reference throttle
SPRINT® is greater for warmer inlet tempera- can then be manually (i.e. by the operator)
tures than for cooler temperatures. Expected advanced further or until the SPRINT® MW
output increase at T2=59°F (15°C) is about 8 limiter is achieved or otherwise limited by T3,
percent and for T2=90°F (32°C) is about 22 T48, or XN25R3 regulators for the case when
percent for engines with steam or water sup- the power turbine droop reference is set to
pression of NOx. For engines operating with- maximum.
out NOx suppression, the expected output
increase will be lower than the previously SPRINT® system can also be manually acti-
mentioned values. vated while at baseload operating conditions
(see packager’s appropriate manual). For spe-
The SPRINT® system will automatically cific details of how to activate the SPRINT®
sequence if the operator selects SPRINT® system, refer to Original Equipment Manufac-
operating mode before (or during) load ramp turer (OEM) operations manual.
(see packager’s appropriate manual). If power is reduced during SPRINT® opera-
When the following conditions are met: tion, the water injection will automatically
shut off when Ps3 drops ≥60 psi below the Ps3
• T2≥30°F, dry schedule. During shutdown a drain valve
is opened to air purge water out of the
• Other site permissives are satisfied, and SPRINT® water supply line to prevent
• Ps3 reaches a level with 50 psid of the freezing.
baseload dry Ps3 schedule.
Water injection flow to the SPRINT® system
SPRINT® is activated, T3 will decrease, and is scheduled as a function of T2. The water
power will automatically ramp increase by the flow ranges from 5 gpm at T2≤40°F to 13.1
ratio of the SPRINT® maximum power limiter gpm at T2≥ 80°F.
to the dry maximum power limiter to achieve
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8-10.2.5 Dual Gas System 8-11.1 Normal Shutdown
Requirements
Under normal operating conditions, the
On systems equipped with provision for oper- LM6000 PC is shut down in the sequence
ation on medium BTU gas (450-650 BTU/ described below.
SCF), the following applies:
a. Power is retarded to minimum load (syn-
a. Starting must occur on standard natural chronous idle) or the control sequencer is
gas meeting requirements of Appendix activated to accomplish the shutdown. The
A1. following should occur:
b. Medium BTU gas must be available for • High pressure rotor speed decreases to
idle and low power operation to purge the approximately 8,400 rpm over a 2-3
main fuel manifold and to provide fuel as minute period.
required for engine operation.
c. Between approximately 50 percent power • T48 decreases.
and baseload when operation is on 100
• Water for NOx suppression will be
percent BTU fuel, the purge valve between
turned off.
the main fuel gas manifold and the starting
gas manifold must be open to provide • If engine is operating on a dual-fuel
purge and thereby prevent backflow of hot mixture, switch to one fuel while at
combustion gas into the starting gas synchronous idle speed.
manifold.
• If steam injection is being used, all fuel
8-11 Shutdown nozzle steam must be turned off.
The following types of engine shutdowns may b. The engine should then decelerate to core
occur: idle speed, approximately 6,100 rpm,
where it should be allowed to cool for 5
Normal shutdown: engine is taken off line
minutes. After 5 minutes, the fuel shutoff
for a specific reason not necessarily related to
valves should be closed and the drain
the engine.
valves opened.
Emergency shutdown: engine is taken off
c. In the case of a post-shutdown fire caused
line by the operator or the control system due
by fuel leaking through the lower fuel noz-
to an engine or system fault.
zles, a rise in T48 will be noticed. With
Other: annunciated fault or other indication fuel valves closed, the engine should be
of problem which operator interprets as a rea- motored on the starter (refer to paragraph
son for taking the engine off line. 8-9 and Chapter 9 of this manual and to
the packager's manual) until T48 starts to
drop, at which point the operator can dis-
continue motoring.
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NOTE After shutdown, natural circulation of 8-11.3 Post-Shutdown Fire
air through the engine must not be inter-
rupted. This includes site air supply to the During a normal shutdown, exhaust gas tem-
compressor rear frame and turbine rear frame perature should decrease following closure of
lube lines/sump walls to avoid coking. Also, the fuel shutoff valves. Under both normal and
flame detector cooling can air circuit airflow emergency shutdowns, a temperature increase
is required for a period of at least 30 minutes (T48) may occur while the engine is coasting
(temperature must be 175°F [79.4°C] or down. This indicates that combustion is con-
lower). tinuing, due to either a leaking fuel valve or
residual fuel trapped in the engine fuel system.
8-11.2 Emergency Shutdown To correct this problem, follow the procedures
described in paragraph 8-9.1 and Chapter 9.
In an emergency, the engine can be shut down
from any power setting. This action can be ini- 8-12 Restart
tiated by the operator or by the packager-sup-
plied control system. An emergency shutdown CAUTION If a questionable condition
automatically initiates the following actions: exists, do not attempt to motor or operate the
engine until a thorough investigation of the
NOTE The information presented herein condition has been made. Do not repeat hot
describes a typical sequence of events. How- starts, compressor stalls, load-shedding, or
ever, for specific control sequencing models other problems that initiate emergency shut-
and site operation information, see the pack- downs or aborted operation without thorough
ager's manual. investigation. Failure to do so can result in
undue stress on engine components that may
a. The fuel valves (and water or steam result in damage or subsequent destructive
valves, if applicable) are closed, the failure of the engine.
VIGVs are closed, and the VBV doors are
opened. The ignition system and starter are This section addresses requirements for
also deenergized, the water pump is turned restarts after operation at power. Restarts may
off, and the XN2, XN25, XNSD, and oil be initiated at any time if the prior shutdown
pressure alarms are bypassed. When these sequence included a cool-down period of 5
steps are completed, drain and vent valves minutes or more at core idle speed, or if cool-
are opened, alarms, interlocks, and start down motoring has been initiated or com-
sequence timers are reset, and the operat- pleted.
ing time meter is turned off.
Restarts following an emergency shutdown or
b. For an emergency shutdown when operat- step decel to idle action from operation at
ing with high-pressure steam injection, the power may be restricted, depending on cause
fuel nozzle steam metering valve and the and if motoring has been initiated within 10
main shutoff valve are closed to stop minutes of HP rotor coastdown. Refer to
steam injection. The steam purge valve is paragraph 8-12.1.
opened to vent pressure behind the meter-
ing valves. The fuel nozzle manifold drain
bleed valve is then opened.
8-20 Change 6
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8-12.1 Hot Restarts Table 8-3 Protective Function Causes Requiring
Resolution Prior to Restart or Motoring
A restart following an emergency shutdown or • Excessive vibration step decel to idle
step decel to idle action from a power level
where T48 is higher than 1,200°F (648.8°C) is • Fire system shutdown and/or Halon
considered a hot restart sequence and should release
not be attempted until the fault or circum- • GT lube oil supply pressure low decel to
stance triggering the shutdown is resolved. It idle
is critical that the hot restart procedure follows
a specific sequence to avoid major engine • Overspeed shutdown (XN25/XN2/
damage. XNSD)
• Enclosure high combustion gas level
An emergency shutdown must be followed by shutdown
a restart or motoring cycle, if possible, to com-
mence no more than 10 minutes after gas tur- • Starter system failure
bine high pressure rotor speed decreases • Fail to crank indication
below 300 rpm. Conditions may not allow
restarting or motoring in some situations, • LPC (XN2)/LPT (XNSD) speed differ-
depending on the cause of the emergency shut- ence shutdown
down, or the status of the starting system. Rea- • dPS3/dT shutdown (stall indication)
sons for not restarting or motoring the gas
• High liquid fuel manifold temperature
turbine following an emergency shutdown are
listed in table 8-3. If restart or motoring cannot shutdown or step decel to idle
be accomplished within 10 minutes, a manda- • Air inlet screen delta pressure high limit
tory lockout of 4 hours is enacted by the con-
trol system to allow sufficient component a. Start the restart timer and initiate a manual
cooling to prevent possible damage to the restart purge. Reset all other timers as
engine. required.
If the fault causing the emergency shutdown is b. Energize the starter to crank the HP rotor
fully understood, resolved, and cleared, and it to a speed not to exceed 2,400 rpm. If the
has been verified that no damage to the engine HP rotor rotates freely, make a normal
has occurred, a restart or motoring sequence start.
can be initiated if the 10 minute limit has not
been exceeded. c. If circumstances allow the HP rotor to be
cranked within 10 minutes after shutdown,
8-12.1.1 Restart Within 10 Minutes a manual purge, if available, will enable a
After Shutdown restart purge cycle to be initiated. The
restart purge cycle motors the engine high
If circumstances permit the shutdown problem pressure rotor to prevent thermal bowing
to be cleared within 10 minutes or less and the of the HP rotor. Starter use for motoring
high pressure (HP) rotor speed is less than 300 the engine HP rotor must be consistent
rpm, the restart procedure is as follows: with limitations specified in Chapter 5.
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d. By selecting the restart purge option, the each period is preceded by normal engine
operator preserves capability to restart the operation.
engine any time after the fault or system
problem has been cleared. • Unlimited windmilling of the engine
rotors is allowed at HP rotor speeds above
8-12.1.2 Restart More Than 10 Minutes 1,000 rpm, provided supply oil tempera-
After Shutdown ture is maintained above 90°F (32.2°C)
and scavenge oil temperature is kept
CAUTION Bypassing this logic and crank- below 340°F (171.1°C). At this speed, the
ing the HP rotor may result in severe HP lube supply and scavenge system operates
compressor rubs and may damage the com- normally, provided positive oil pressure is
pressor blades and vanes. maintained and oil cooling is provided.
If it is not possible, or desirable, to initiate the 8-14 Engine Performance
restart purge cycle or a cool-down motoring
cycle within 10 minutes after the HP rotor has Following installation and checkout, the
coasted to below 300 rpm, the control system engine should be operated at various speed/
will then lock out any further attempts to load conditions in order to establish baseline
restart or motor the engine for a period of 4 performance for the specific installation. Refer
hours. to paragraph 8-10.1c. and table 8-1.
After 4 hours, a normal start sequence may be The operator should record, as a minimum, the
initiated. following engine/facility parameters in order
to monitor engine performance:
8-13 Windmilling
• Inlet air temperature
Windmilling is generally caused by air forced
through the inlet, causing the rotors to turn at • Barometer (local)
relatively low speeds of less than 100 rpm.
Windmilling also occurs during shutdown as • T25
the kinetic energy of the rotor is dissipated by
the pumping and rolling-element friction. The • P2
windmilling limits below should be observed
• T3
to avoid rolling element life reduction.
• P3
• There is no provision for unrestricted
windmilling operation. However, the flow • T48
of air through the engine must not be
restricted during the engine cool-down • LP rpm (XN2, XNSD)
period.
• HP rpm (XN25)
• Both engine rotors may windmill for up to
7 days at speeds up to 100 rpm, provided • Fuel flow (WF)
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8-3
• Supply oil temperature The Performance Data Sheet shows typical
parameters and precision levels which would
• Scavenge oil temperature normally be required for a performance evalu-
ation by GE.
• Supply oil pressure
• Load (facility) Other considerations for best accuracy:
• CRF accelerometers • Instrumentation should be recently
calibrated
• TRF accelerometers
• VG systems should be rig checked and
8-14.1 Performance Measurement calibrated
A log of all LM6000 PC running time should • Crank soak washing should be performed
be kept. The following minimum data should prior to test
be recorded:
• Fuel sample should be collected and
• Time of all starts and shutdowns analyzed for lower heating value (LHV)
and specific gravity (SG) to assist in expe-
• Total time since installation dited analysis of performance data. Liquid
fuel is to be analyzed for contaminants and
• Twice daily log of all instrument readings, compliance with fuel specification
taken at the set-load point
• High power data readings should be taken
• All changes in speed or load with VBV closed
• Adjustments and part changes The same data should be used for periodic
trending of engine performance.
• Preventive maintenance action
8-14.3 Component Life/Repair Intervals
• Lease pool installation, removal, run time
Safe operation of the LM6000 PC is depen-
8-14.2 Performance Data Recording dent on properly scheduled maintenance,
repairs, and component replacement. In order
For diagnosing performance or emissions
to properly track these conditions, packager-
issues, best results are obtained when all the
supplied time and event counters provide data
parameters in the Performance Data Sheet,
for the parameters listed in table 8-4.
figure 8-4, are recorded and the data is
recorded to the indicated level of precision. The operator is responsible for maintaining a
Also for best accuracy in the analysis, the log of the operating data parameters for gas
engine should be stabilized for at least 5 min- turbine components. This will require that the
utes prior to data recording and several (3-5) operator track components that are removed
readings should be taken at a given power during field or depot maintenance.
level
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Figure 8-4 LM6000 Performance Data Sheet (Sheet 1 of 4)
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Figure 8-4 LM6000 Performance Data Sheet (Sheet 2 of 4)
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Figure 8-4 LM6000 Performance Data Sheet (Sheet 3 of 4)
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Figure 8-4 LM6000 Performance Data Sheet (Sheet 4 of 4)
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Table 8-4 Operating Data Parameters
Parameter Description
TH Total hours, all operation
TFS Total fired starts
TT Total trips (emergency shutdowns and step decels to idle)
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5 CHAPTER 9
Abnormal Operation
9-1 Purpose and Scope • Shutdowns
This chapter covers abnormal operating condi- 9-3.1 Alarms
tions and procedures, and control-provided
auto-protective features. It provides defini- Alarms are used to alert the operator to a con-
tions, descriptions, and operator actions dition that requires operator intervention.
required for abnormal conditions resulting in Some alarms may simply indicate that a con-
alarms or protective action. It also covers dition has been reached that will require main-
other conditions that do not trigger alarms or tenance in a short time. Other alarms indicate
protective action, but which require special that a condition has been reached that may
action by the operator. lead to the initiation of a protective function if
positive corrective action is not taken immedi-
9-2 General Definitions ately. Reference the Troubleshooting Refer-
ence Table in Chapter 10 for the problem
Abnormal operation is defined as any type of events and system conditions that trigger
LM6000 PC operating condition that: alarms and protective functions.
• Deviates from normal operating limits
9-3.2 Power Cutback
• Exceeds normal operating limits
A power cutback is accompanied by an alarm.
• Causes an alarm or other protective action There is one power cutback function that can
to be initiated be initiated by the control:
A protective function is defined as any action • Slow decel to minimum load
initiated automatically by the packager's con-
trol in order to: 9-3.2.1 Slow Decel to Minimum Load
• Prevent damage to the LM6000 PC engine A slow decel to minimum load (min-load) is a
or installation controlled deceleration at a rate that allows all
engine schedules and engine cooling to be
• Prevent injury to personnel
maintained at a controlled rate.
9-3 Control Actions
The decel rate for a slow decel is approxi-
There are three levels of protection initiated mately 100 rpm/s (XN25). Rather than decel
by the LM6000 PC packager-supplied control all the way to core idle, the engine decels to
system when abnormal conditions are sensed: the min-load point. This allows the condition
to be investigated without requiring a shut-
• Alarms (alarm-only conditions) down. There is no time limitation for remain-
ing at min-load, unless the condition requiring
• Power cutbacks this decel still persists, in which case a normal
shutdown sequence is initiated.
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9-3.3 Shutdowns • The variable bypass valves (VBVs) are
opened (closed later during coastdown)
All shutdowns are accompanied by an alarm.
There are four shutdown functions that can be • Underspeed and oil pressure alarms are
initiated by the control: bypassed
• Emergency shutdown (gas turbine motor- • Drain and vent valves are opened per con-
ing allowed) trol sequencing
• Emergency shutdown (gas turbine motor- • Alarms, interlocks, sequence timers, and
ing not allowed) operating timers are reset
• Step decel to idle The emergency shutdown will not allow reset
until core speed (XN25) is less than 400 rpm.
• Abort start Table 8-3 outlines the protection functions that
require root cause resolution prior to engine
All alarm and protective function setpoints are motoring.
based on typical applications with driven
equipment rated for continuous duty operation 9-3.3.3 Step-Decel to Idle/Shutdown
at 3,600 rpm.
A step-decel to idle is an immediate rapid
9-3.3.1 Shutdown (max decel rate) deceleration to idle followed
by a 10 second pause, and then by a shutdown.
A control initiated shutdown is a controlled A step-decel provides a more controlled and
decel to idle, a 5 minute stabilization period, orderly way of shutting down the engine than
and a shutoff of the fuel valves and opening of does an immediate shutdown at power. The
the fuel staging valves. 10 second pause at core idle allows various
scheduled engine systems, such as variable
9-3.3.2 Emergency Shutdown
inlet guide vanes (VIGVs) and VBVs, to reach
An emergency shutdown is initiated by the a stabilized condition before shutdown occurs.
control when the engine must be shut down
When a step-decel occurs, the control initiates
immediately in order to prevent severe dam-
the following sequence of events:
age to the engine or installation.
a. Power is immediately reduced to core idle,
When an emergency shutdown occurs, the
causing the engine to decel as rapidly as
control initiates the following events:
possible.
• The fuel shutoff valves and metering valve
b. When the engine reaches core idle speed,
are closed
the control holds it at idle for 10 seconds
• The gas blowoff valve is opened and then initiates a shutdown. The hold at
core idle allows the engine to be shut
down from an on-schedule, stabilized con-
dition.
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c. When the control initiates the shutdown • Underspeed and oil pressure alarms are
after the 10 second idle hold, the following bypassed
events occur:
• Drain and vent valves are opened per con-
• The fuel shutoff valves are closed trol sequencing
• The VBVs are closed during coast- • Alarms, interlocks, sequence timers, and
down operating times are reset
• Underspeed and oil pressure alarms • A purge cycle is initiated by the control, if
are bypassed applicable
• Drain and vent valves are opened per 9-4 Operator Action
control sequencing
In order to avoid more severe protective
• Alarms, interlocks, sequence timers, action, the operator must address the causes of
and operating timers are reset all alarms and determine corrective actions
necessary to clear abnormal conditions.
9-3.3.4 Slow Decel to Minimum Load/ Before resuming normal engine operation
Shutdown after a power cutback or shutdown, positive
action to correct the cause is necessary. For
A slow decel to minimum load involves the any alarm or protective action, the following
fuel control controlling gas turbine decelera- general procedures should be followed:
tion at a rate of core speed equal to 100 rpm/
sec. or low pressure rotor speed equal to a. Acknowledge the alarm in the manner
9 rpm/sec. After core idle is reached, the specified in the packager's manual.
sequence of events is the same as a step-decel
to idle/shutdown. b. Reduce power, if necessary, and take
whatever steps possible to prevent further
9-3.3.5 Aborted Start alarms or more severe protective action.
Reducing power to eliminate an alarm
An abort is initiated at any time during the without investigation of alarm root cause
start sequence when certain parameters exceed is unacceptable. Significant damage to the
limits. During an aborted start, the control ini- engine can occur if alarms are bypassed.
tiates the following events:
c. Consult the troubleshooting procedures in
• The fuel shutoff valves are closed Chapter 10 of this manual.
• The ignition system and starter are de- d. During an alarm-only condition, correct
energized the problem, if possible, and resume nor-
mal operation. If recovery is not possible,
• The VBVs are closed during coastdown shut down and correct the problem; refer
to the packager's manual for more specific
information.
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e. After a power cutback, correct the problem When T48 returns to normal, discontinue
before resuming operation at power. If motoring. Refer to post-shutdown fire in
recovery is not possible, shut down and Chapter 8 and troubleshooting procedures in
correct the problem. Chapter 10.
f. After a shutdown, correct the problem 9-7 Special Inspections
before attempting a restart.
a. The maintenance of the gas turbine
CAUTION If motoring within 10 minutes requires that inspection checks be made
after the HP rotor (XN25) is rotating at less periodically. The inspection requirements
than 300 rpm is not possible, do not attempt and limits throughout this manual are
to motor the engine for at least 4 hours. Any based on operation within specified limits.
attempt to motor the engine sooner may In addition to the regular inspections, there
result in severe damage to the engine. are special inspections necessary when the
gas turbine has been operated outside of
g. If possible without causing damage, motor the specified limits, for example, off-
the engine for cooling within 10 minutes schedule variable-geometry operation,
of the time the high pressure (HP) rotor overspeed, or overtemperature. There also
(XN25) is rotating at less than 300 rpm. may be special inspections necessary if the
Refer to Chapter 8. gas turbine has been exposed to abnormal
h. Enter appropriate comments in the engine conditions. These events include failures
run log (Chapter 8) concerning any prob- with significant damage and other abnor-
lems and corrective action. mal exposure such as an installation fire or
mishap during transportation, handling, or
9-5 Hot Restarts storage. Some of the abnormal conditions
to which an engine may be exposed are:
A hot restart is defined as any attempt to start
the engine immediately following emergency • Shock loading, collision impact, expo-
shutdown or a trip-from-power shutdown. A sure to explosion, handling or trans-
hot restart should not be attempted until the portation mishap
fault or circumstance triggering the shutdown • Structural overstress, mounting system
is resolved. It is critical that the hot restart pro- overload to gas turbine interface (e.g.,
cedure follows a specific sequence to avoid earthquake, installation error)
major engine damage. Refer to Chapter 8 for
hot restart procedures. Refer to Chapter 10 for • Any equipment failure where parts are
troubleshooting procedures. not contained within the gas turbine, or
where a major rotating component sep-
9-6 Post-Shutdown Fire arates
During a normal shutdown, T48 should • Sudden seizure or stoppage of the gas
decrease. An increasing T48 during coast- turbine rotor(s) or driven equipment
down is an indication of continued combus- rotors
tion, possibly due to a leaking fuel valve. To
correct this condition, shut off the fuel supply • Excess G-loading during operation in
and motor the engine to blow out the fire. excess of packager manual limits
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• Significant inlet ingestion events (e.g., facturing, operation within defined limits, and
foreign objects causing significant maintenance within defined limits and pro-
flowpath damage, ice ingestion, inlet cesses, as well as by inspection. Parts exposed
system failure) to abnormal conditions may appear to be ser-
viceable when, in fact, the actual state of the
• Exposure to external fire, involving
material cannot be ascertained even by the
inlet system, exhaust system, base
most advanced non-destructive testing and
enclosure, and equivalent
inspection methods. Parts which have been
• Exposure to external fire in storage or involved in an abnormal event must be for-
transport mally reviewed for severity of operation
beyond the normal working environment and
• Internal fire
dispositioned as to the necessity for a special
• Thermal quench by water or other inspection workscope. The operator has the
agent, local overheating by fuel or responsibility for the continued safe operating
steam system failure condition of the gas turbine. Since used
replacement parts may be available which
• Exposure to corrosive chemicals, fire-
have operated in abnormal events, the operator
fighting agents, salt water, or sewage
should verify that the service histories of these
These events are highly variable and the expo- parts are known and that, when applicable, the
sure and associated damage which a gas tur- required special inspections and part disposi-
bine experiences is unpredictable. This tion following exposure to abnormal condi-
prevents establishing a single, all-inclusive tions have been completed and the part is
inspection and repair procedure. Depending serviceable.
upon the circumstances of the event, instances
b. Similarly, many components or assemblies
of localized, limited damage can often be dis-
from aircraft engines which have experi-
positioned by normal channels. For abnormal
enced previous flight service are not
events, such as the events listed above, execu-
usable in LM engines. In addition, gas tur-
tion of a special inspection workscope is nec-
bine components which have experienced
essary for proper restoration of serviceability.
an extremely high number of start/stop
In some extreme cases, repair may not be pos-
cycles may not be usable. Specifically, use
sible or economical, and, therefore, further
of used-serviceable flight or high-cycle
repair effort may not be advisable. Before pro-
engine parts in the following categories is
ceeding with inspection or repair action to
prohibited:
restore serviceability after a mishap, contact
the following for guidance: (1) Rotating components
GE Aircraft Engines (2) Stator cases and stator vanes
Marine & Industrial Customer Service (3) Frame assemblies, including sump
Mail Drop S-155 components
1 Neumann Way
Cincinnati, Ohio 45215-1988 USA (4) Main shaft bearings
Assurance of a part's serviceability is derived Prior to use of other components, contact
from control of material processing and manu- Marine & Industrial Engines Customer Ser-
vice about usability.
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CHAPTER 10
Troubleshooting
10-1 Purpose and Scope alarms, control actions, and the setpoints that
trigger these alarms or control actions. These
This chapter provides general troubleshooting are grouped by major engine/facility systems.
procedures for the LM6000 PC gas turbine. Each event also lists a numbered Trouble-
shooting Procedure (TS-) or a SPAM (See
10-2 Arrangement and Use Packager’s Appropriate Manual) reference.
This chapter includes two major segments: a At the end of the Troubleshooting Reference
Troubleshooting Reference Table and a set of Table, items in the Miscellaneous category
numbered Troubleshooting Procedures. For either (1) do not trigger an alarm or control
ease of use, the Troubleshooting Reference action or (2) are a combination of conditions,
Table and Troubleshooting Procedures follow some of which may or may not trigger an
these introductory and explanatory sections. alarm or control action on their own, that must
Figures and tables are presented at the end of also be looked at in combination with others.
the section.
10-2.2 Numbered Troubleshooting
Figure 10-1 provides a control system compo- Procedures
nent schematic as an aid to troubleshooting.
The numbered Troubleshooting Procedures
Engine/package electrical interface panels are (TS-1 through TS-32) are referred to in the
illustrated in figure 10-2. Engine interface Troubleshooting Reference column of the
connectors are indicated in the schematics of Troubleshooting Reference Table. These pro-
figures 10-3 through 10-26. Figures 10-3 cedures show symptoms for each engine or
through 10-26 are cited in the numbered facility condition, possible causes for each, the
Troubleshooting Procedures. troubleshooting procedure to isolate the cause
of the problem, and the recommended correc-
Tables 10-1 through 10-10 are cited in, and tive action. Events or conditions in the Trou-
provide supplementary information for, bleshooting Reference Table that have only a
some of the numbered Troubleshooting SPAM reference are not discussed in the num-
Procedures. bered troubleshooting procedures.
10-2.1 Troubleshooting Reference Table 10-10 shows maximum allowable
Table instrumentation and accessory temperatures.
The Troubleshooting Reference Table shows
various problem events and system conditions,
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10-2.3 Using This Chapter These instructions may not provide for every
possible variation in equipment or contin-
The steps shown below illustrate how to use gency to be met in connection with the opera-
this chapter for troubleshooting. tion of the engine. Refer requests for
additional information to the packager.
NOTE Symptoms, possible causes, trouble-
shooting procedures, and corrective actions 10-3.1 Low Pressure Turbine Speed
are grouped horizontally across each page, Sensor (XNSD) Testing
allowing each symptom or set of symptoms to
have more than one possible cause. Each pos- NOTE
sible cause may also have more than one trou-
bleshooting procedure, and each • This procedure is only for the XNSD speed
troubleshooting procedure may have more sensor, PN L44684.
than one corrective action.
• XNSD speed sensor, PN L44684, can only
Example - Alarm received for air inlet differ- be tested on the secondary winding. This
ential pressure high: test cannot confirm a good sensor, but it
can confirm a bad sensor. The evaluation
a. Find the air inlet differential pressure high that follows is only for determining that a
entry on the first page of the Troubleshoot- sensor is bad.
ing Reference Table.
WARNING Alcohol is flammable and toxic
b. Refer to troubleshooting procedure TS-3, to skin, eyes, and respiratory tract. Skin
as listed in the Troubleshooting Reference and eye protection is required. Avoid
column. repeated or prolonged contact. Use in a
well-ventilated area.
c. Follow the appropriate procedure for each
possible cause listed in TS-3. a. Ensure the inside of the sensor connector
is not dirty or wet before performing the
10-3 Troubleshooting Procedures following tests. If dirt or fluids are seen
inside connector, this may explain an
WARNING If a questionable condition improper XNSD signal indication. Use
exists, do not operate the engine until a only denatured alcohol to rinse and clean
thorough investigation has been made. Do inside of connector.
not repeat hot starts, compressor stalls, or
other recognized problems without prior b. Using an ohmmeter, measure resistance
thorough investigation, root cause determi- across two pins. Resistance should be
nation, and corrective action. Failure to do same measuring in either direction. Resis-
so can result in undue stress being imposed tance value between pins of a good XNSD
on engine components, with immediate or sensor should be 500-2000 ohms. If read-
subsequent destructive failure of the engine ing is outside these limits, ensure a good
and injury to personnel. connection exists between ohmmeter leads
and pins, and repeat reading. If indication
is still outside limits, replace sensor.
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c. Measure resistance from each pin to case, b. Calculate and record the current 1B bear-
one at a time. Both measurements should ing load using the following equation:
indicate above 500,000 ohms. If either
indication is less than 500,000 ohms, • 1B Axial Load = 55901 - 192260 x
replace sensor. The actual reading could be (PTBSEL/PS3SEL) + 295 x P48SEL
over 5 megohms. - 995 x P25SEL.
d. When starting engine, note speed at which c. Record current orifice plate part number,
control begins to display engine speed. IGV system, SPRINT® system, and total
Speed indication should appear before operating time (hours) since new or last
engine reaches 350 rpm, with 200 rpm full overhaul. Record engine configuration
being nominal highest (worst case) value. and conditions as follows:
If first indication is above 350 rpm, repeat
steps b. and c. to validate sensor. If values (1) Configurations of engines:
are in range per steps b. and c., reset sen-
• Configuration 1 = Fixed IGV to
sor, using a slight twisting action to fully
0°F (0°C), non-SPRINT®
seat sensor. If control continues to give
first indications above 350 rpm, switch • Configuration 2 = VIGV,
positions of the two sensors in LPT to
non-SPRINT®
determine if the first indication speed is
reduced to a better value. If not, the defec- • Configuration 3 = Fixed IGV to
tive sensor should indicate out-of-range in 0°F (0°C), with SPRINT®
both positions, and if so, should be
replaced. • Configuration 4 = VIGV, with
SPRINT®
10-3A Adjustment of Engine
Balance Piston Pressure • Configuration 5 = Fixed Open
IGV to -5°F (-20.6°C),
Using data input sheet table 10-3A.1 to record non-SPRINT®
data information, verify thrust-balance load as
follows: • Configuration 6 = Fixed Open
IGV to -5°F (-20.6°C), with
a. Start gas turbine per normal start proce- SPRINT®.
dure. Accel to maximum power, greater
than 30 MW, stabilize for 20 minutes and (2) Engine conditions:
record operating parameters PTBSEL,
PS3SEL, P48SEL, P25SEL, and T2SEL. • New = new or fully overhauled
Shut down per normal shut down proce- engine with less than 1000 hours
dures. since new or last overhaul
• Deteriorated = used engine with
greater than 1000 operating hours
since new or last overhaul.
Change 6 10-3
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Volume I GE Industrial AeroDerivative Gas Turbines
d. Identify target thrust bearing balance load f. Calculate and record the change in orifice
from the appropriate target load curves diameter needed to reach target load. Use
(Refer to figure 10-3A.1 through the following equation:
figure 10-3A.13). As an alternative, the
target bearing load can be identified from • Change in orifice diameter = load dif-
the data in table 10-3A.2 and ference / -109,140.
table 10-3A.3. Record target 1B bearing
load. g. Record current orifice diameter from
table 10-11 onto data sheet in
NOTE The calculated bearing load should be table 10-3A.1. Calculate and record the
between 2000-16000 pounds (907-7257 kg). required/predicted orifice plate diameter
If the calculated bearing load is within onto data sheet table 10-3A.1 as follows:
2000-16000 pounds (907-7257 kg), an orifice
change is not required unless an anticipated • Required/predicted orifice plate diam-
change in ambient temperature could result eter = current orifice plate - change in
in the calculated bearing load exceeding orifice diameter.
16000 pounds (7257 kg) or be less than
h. Select the orifice plate that is closet in
2000 pounds (907 kg).
diameter to the required/predicted diame-
Example: Engine is operated with a T2SEL of
ter. Refer to table 10-11. Record selected
20°F (16.7°C) and the calculated load is
orifice plate part number using data sheet
12000 pounds (5443 kg). The change in load
in table 10-3A.1.
required is 1500 pounds (680 kg). If the engine
is expected to operate at a T2SEL of 55°F i. Install orifice plate per WP 1714 00.
(12.8°C), there is a potential that the bearing Repeat paragraphs 1 through 9 as required.
load will exceed 16000 pounds (7257 kg) (tar-
get load at 55°F (12.8°C) from table plus
change load required to meet target). Refer to
figure 10-3A.13.
e. Calculate and record the load difference.
Use the following equation:
• Load difference = target load - current
load.
10-4 Change 6
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Table 10-3A.1 No. 1B Bearing Thrust Balance Orifice Selection Worksheet
LM6000 Engines with Thrust Balance Kit, 682L928
Data Input
Site:
Model:
ESN:
Date:
Power (MW)
PTBSEL (psia)
PS3SEL (psia)
P48SEL (psia)
P25SEL (psia)
T2SEL (degrees F)
Current Orifice Plate: P/N L49438 or L52177 (P0x)
Does the engine contain a VIGV System? (Y/N)
If Fixed IGV, is it the new -5°F (-20.6°C) fixed open configuration? (Y/N)
Is the engine operating with a SPRINT® Water System? (Y/N)
Anticipated Site min T2 (default to -65°F [-53°C])
Anticipated Site max T2 (default to 140°F [60°C])
Total Operating Time (hours)
Calculations
1B Bearing Load Algorithm equation:
1B Axial load = 55,901 - 192,260 (PTB/PS3SEL) + 295 (P48SEL) - 995 (P25SEL)
Current 1B Bearing Load (pounds)
Configuration of Engine
Condition of Engine
Data Table or figure used
Current Orifice Diameter (inches)
Target 1B Bearing Load (pounds)
Change in 1B Load required (pounds)
Orifice Plate Sizing equation:
Change in Orifice Diameter = (Change in 1B Load required) / (-109,140)
Amount of change required in Orifice Diameter (inches, + is larger)
Predicted Orifice Diameter (inches)
Notes:
1. Orifice plate shall be sized for long-term operating conditions.
2. All recorded pressure measurements are absolute (psia).
3. All recorded temperature measurements are degrees Fahrenheit.
4. Engine must be at a Steady State operating condition >30 MW for 20 minutes.
5. Total Operating Time to be lesser of Time Since New or Time Since Major Overhaul.
6. Engines operating continuously at MAX Power are expected to use orifice plate diameters = 0.810 inch
(20.57 mm) (P05).
7. Engines operating continuously at less than MAX Power are expected to use orifice plate diameters
>0.810 inch (20.57 mm).
Change 6 10-5
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Table 10-3A.2 New LM6000 PC Engine - Nominal No. 1B Bearing Loads Data Sheet
Table 1 Table 2 Table 3 Table 4 Table 5 Table 6
FIGV Non- VIGV, Non- FIGV, with VIGV, with FOIGV, Non- FOIGV,
T2SEL
SPRINT®, SPRINT®, SPRINT®, SPRINT®, SPRINT®, SPRINT®,
New New New New New New
-65 5,091 9,635 4,950 9,566 4,443 4,315
-60 5,553 9,611 5,419 9,541 5,073 4,932
-55 6,003 9,596 5,870 9,527 5,648 5,531
-50 6,457 9,662 6,318 9,604 6,224 6,105
-45 6,883 9,809 6,762 9,750 6,778 6,673
-40 7,316 9,993 7,190 9,934 7,445 7,338
-35 7,480 10,132 7,363 10,064 7,581 7,472
-30 7,719 10,276 7,604 10,149 7,694 7,579
-25 7,943 10,360 7,752 10,150 7,781 7,598
-20 7,936 10,054 7,738 9,882 7,503 7,318
-15 7,975 9,868 7,771 9,701 7,342 7,149
-10 7,926 9,688 7,573 9,525 7,222 6,935
-5 7,832 9,513 7,421 9,347 6,942 6,662
0 7,723 9,333 7,330 9,171 6,674 6,397
5 7,928 8,898 7,624 8,711 6,689 6,487
10 8,434 8,536 8,116 8,366 6,871 6,673
15 8,917 8,218 8,611 8,043 7,077 6,881
20 9,325 7,905 9,062 7,731 7,412 7,161
25 9,674 8,064 9,520 7,805 7,811 7,581
30 10,030 8,871 11,227 10,277 8,321 9,806
35 10,439 9,536 11,633 10,736 9,133 10,434
40 10,507 9,981 12,024 11,169 9,684 10,883
45 10,049 9,640 13,354 12,422 9,449 12,120
50 9,391 8,658 14,098 13,031 8,409 12,728
55 8,366 7,692 14,605 13,650 7,547 13,353
60 7,522 6,882 14,553 14,288 6,835 13,968
65 6,572 6,305 14,255 13,999 6,106 13,890
70 5,871 6,294 13,925 13,647 5,552 13,536
75 5,356 6,327 13,557 13,276 5,060 13,155
80 4,921 6,290 13,195 12,894 4,317 12,803
85 4,440 6,265 12,741 12,529 3,863 12,277
90 4,414 6,260 12,124 12,234 3,178 11,657
95 4,258 6,229 11,280 11,956 2,625 10,817
100 3,652 6,260 10,397 11,517 2,096 10,136
105 2,775 6,260 9,698 11,062 1,450 9,200
110 2,025 6,338 9,311 10,683 1,011 8,380
115 1,528 6,617 9,143 10,585 630 7,852
120 1,256 7,071 8,570 10,427 422 7,113
125 1,479 6,865 7,957 10,337 1,192 6,657
130 1,533 5,870 7,389 10,222 1,364 6,373
135 2,130 5,065 7,175 10,471 1,778 6,261
140 2,633 4,876 7,001 10,845 2,090 6,163
10-6 Change 6
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Table 10-3A.3 Deteriorated LM6000 PC Engine - Nominal No. 1B Bearing Loads Data Sheet
Table 7 Table 8 Table 9 Table 10 Table 11 Table 12
FIGV, Non- VIGV, Non- FIGV, with VIGV, with FOIGV, Non- FOIGV,
T2SEL
SPRINT® SPRINT® SPRINT® SPRINT® SPRINT® SPRINT®
Deteriorated Deteriorated Deteriorated Deteriorated Deteriorated Deteriorated
-65 4,756 8,592 4,610 8,548 3,922 3,783
-60 5,232 8,592 5,087 8,537 4,530 4,396
-55 5,741 8,602 5,580 8,532 5,138 4,993
-50 6,216 8,678 6,043 8,641 5,743 5,583
-45 6,676 8,834 6,514 8,796 6,321 6,176
-40 7,093 9,006 6,963 8,965 6,927 6,812
-35 7,091 9,151 6,966 9,106 7,068 6,960
-30 7,213 9,280 7,107 9,193 7,202 7,086
-25 7,443 9,362 7,251 9,192 7,298 7,107
-20 7,258 9,020 7,038 8,855 6,978 6,786
-15 6,984 8,791 6,738 8,511 6,612 6,360
-10 6,673 8,465 6,427 8,186 6,222 5,981
-5 6,451 8,138 6,152 7,855 5,883 5,612
0 6,283 7,812 5,988 7,532 5,625 5,352
5 6,347 7,210 6,132 7,057 5,655 5,462
10 6,617 6,937 6,368 6,791 5,851 5,660
15 7,031 6,707 6,774 6,552 6,060 5,868
20 7,450 6,495 7,184 6,335 6,279 6,064
25 7,973 6,448 7,702 6,217 6,470 6,276
30 8,624 7,060 10,225 8,688 6,893 8,472
35 9,389 7,774 10,715 9,429 7,448 9,026
40 9,900 8,609 11,140 10,160 8,057 9,666
45 9,197 8,403 12,333 11,476 8,157 11,217
50 8,089 7,382 12,899 12,085 7,250 11,824
55 7,172 6,462 13,111 12,726 6,426 12,408
60 6,243 5,640 13,108 12,898 5,842 12,816
65 5,522 5,347 12,932 12,730 5,264 12,651
70 4,970 5,384 12,779 12,584 4,737 12,503
75 4,499 5,412 12,601 12,354 3,937 12,243
80 4,050 5,143 12,267 11,995 3,309 11,897
85 4,031 5,115 11,782 11,577 2,988 11,435
90 4,017 5,147 11,273 11,323 2,413 10,773
95 3,481 5,257 10,423 10,969 1,765 10,149
100 2,739 5,309 9,732 10,602 1,261 9,355
105 1,855 5,421 9,211 10,139 713 8,468
110 1,150 5,588 9,073 9,777 283 7,824
115 757 5,995 8,607 9,675 -58 7,202
120 735 6,636 7,832 9,574 273 6,396
125 797 6,056 7,261 9,541 693 6,117
130 1,278 4,878 6,809 9,435 987 5,808
135 1,823 4,476 6,577 9,664 1,317 5,591
140 2,255 4,360 6,478 10,044 1,595 5,919
Change 6 10-7
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Figure 10-3A.1 Fixed IGV to 0 Degrees, Non-SPRINT®, New Engine
Figure 10-3A.2 VIGV, Non-SPRINT®, New Engine
10-8 Change 6
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Figure 10-3A.3 Fixed IGV to 0 Degrees, with SPRINT®, New Engine
Figure 10-3A.4 VIGV, with SPRINT®, New Engine
Change 6 10-9
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Figure 10-3A.5 Fixed Open IGV to -5 Degrees, Non-SPRINT®, New Engine
Figure 10-3A.6 Fixed Open IGV to -5 Degrees, with SPRINT®, New Engine
10-10 Change 6
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Figure 10-3A.7 Fixed IGV to 0 Degrees, Non-SPRINT®, Deteriorated Engine
Figure 10-3A.8 VIGV, Non SPRINT®, Deteriorated Engine
Change 6 10-11
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Figure 10-3A.9 Fixed IGV to 0 Degrees, with SPRINT®, Deteriorated Engine
Figure 10-3A.10 VIGV, with SPRINT®, Deteriorated Engine
10-12 Change 6
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Figure 10-3A.11 Fixed Open IGV to -5 Degrees, Non-SPRINT®, Deteriorated Engine
Figure 10-3A.12 Fixed Open IGV to -5 Degrees, with SPRINT®, Deteriorated Engine
Change 6 10-13
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Figure 10-3A.13 Potential Load at 55°F
10-14 Change 6
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10-4 Troubleshooting Reference Table
Except where otherwise indicated, each event shown in this table is accompanied by an alarm, regardless of whether it is accom-
LM6000 PC
panied by a control action. Limits are shown in the alarm column for events resulting in an alarm only. Events that have both an
alarm and an accompanying control action will show the limits in the appropriate action column and an X in the alarm column.
In cases where one limit triggers an alarm only and a higher limit triggers both an alarm and control action, the limits for each
will be shown in the appropriate columns. In any case that has no particular limits and is simply an either/or condition, the alarm
and/or control action will be indicated by X in the appropriate columns.
Air Inlet System
Step Decel to
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
GE Industrial AeroDerivative Gas Turbines
Air Inlet Differential <0, >10 in H2O 1 SPAM
Pressure, Sensor Failure (<0, >2.49 kPa) (see packager’s
appropriate
manual)
Air Inlet Differential dP > dPi +1.0 in H2O dP > dPi +2.0 in H2O 1 TS-3
Pressure, High (dP >dPi + 0.25 kPa) (dP >dPi + 0.50 kPa)
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
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Volume I
GEK 105059
10-15
Combustion System
10-16
Step Decel to
Volume I
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
GEK 105059
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
Flame loss, Both Sensors, X Flameout > 300 ms 3 TS-4
XN25 >9,500 rpm SPAM
Flame loss, Both Sensors, Flameout > 300 ms 3 TS-4
XN25 >9,500 rpm SPAM
Change 6
Flame loss, One Sensor X TS-29
(No Flameout) SPAM
Post Shutdown Fire 37 TS-2
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Facility Systems
Step Decel to
Shutdown or Core-Idle,
Emergency Shutdown Slow Decel to Troubleshooting
LM6000 PC
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
MW Sensor Failure <0, >48 MW SPAM
PGAS Sensor Failure <10, >800 psia 8 SPAM
(<69, >5,516 kPa)
Power Supply Failure X X 9 TS-5
SPAM
High Enclosure Temperature 37 TS-31
SPAM
GE Industrial AeroDerivative Gas Turbines
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Change 6
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Volume I
GEK 105059
10-17
Fuel System
10-18
Step Decel to
Volume I
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
GEK 105059
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
Liquid or Gas Fuel Shutoff X X 5 TS-22
Valve Cycling SPAM
Fuel Supply Temperature, Gas Fuel: 2 TS-6
Below Limit < TSV + 20°F 29 SPAM
Change 6
(< TSV + 11°C)
Liquid Fuel:
< TWP + 20°F or
temperature to meet
viscosity
requirements of MID-
TD-0000-2 35°F
(1.7°C) is the
minimum
temperature
(< TWP + 11°C)
Fuel Supply Temperature, Gas Fuel: 2 TS-6
Sensor Failure < -40°, >380°F 29 SPAM
(<-40°, >193°C) SPAM
Liquid Fuel:
< -40°, >200°F
(<-40°, >93°C)
Fuel Supply Temperature, X Gas Fuel:
High >300°F (149°C)
Liquid Fuel:
>150°F (66°C)
Liquid Fuel Filter ΔP, Sensor <0, >60 psid TS-7
Failure (<0, >414 kPa)
Liquid Fuel Filter ΔP, High >30 psid TS-7
(>207 kPa) SPAM
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Liquid Fuel/Water Manifold >450°F (>232°C) >700°F (>371°C) >600°F (>315°C) 31 TS-8
Overtemperature SPAM
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
Liquid Fuel/Water Manifold X >-40°, >1000°F 31 TS-27
Temp Sensor Failure, Both (>-40°, >538°C) SPAM
Sensor
GE Industrial AeroDerivative Gas Turbines
LM6000 PC
Fuel System (Continued)
Step Decel to
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
LM6000 PC
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
Fuel Manifold Pressure Too 37 TS-22
High or Too Low
Liquid or Gas Fuel Shutoff X X 5 TS-22
Valve Cycling or Slewing SPAM
Wide Open at Start
Liquid Fuel Pump Inlet >50 psig SPAM
Pressure, High (>345 kPa)
Liquid Fuel Pump Inlet -5 psig 30 SPAM
Pressure, Low (-35 kPa)
GE Industrial AeroDerivative Gas Turbines
Liquid Fuel Pump Inlet <0, >300 psig SPAM
Pressure, Sensor Failure (<0, >2,068 kPa)
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Volume I
GEK 105059
10-19
HPC System
10-20
Step Decel to
Volume I
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
GEK 105059
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
PS3 A/B Difference Over > 10 psia SPAM
Limits (>69 kPa)
PS3 Sensor Failure, One or <10, >480 psia 4, 10 SPAM
Both Sensors (<69, >3,309 kPa)
Change 6
Stall X -dPS3/dt> Threshold 21, 22 TS-9
for > 20 msec
Starting Stall 37 TS-1 and TS-9
T25 A/B Difference Over >18°F TS-27
Limits (>-8°C)
T25 Sensor Failure, One or One Element: Both Elements: 4, 13, 18 TS-27
Both Elements <-40°, >380°F <-40°, >380°F
(<-40°, >193°C) (<-40°, >193°C)
P25 Sensor <10, >40 psia SPAM
(<69, >276 kPa)
T3 A/B Difference Over Limit >20°F TS-27
(>-7°C)
T3 Sensor Failure, One or <-40°, >1,200°F 4, 14 TS-27
Both Elements (<-40°, >649°C)
T3 Reads Low/High 37 TS-27
Decreases or Goes Negative
During Lightoff
XN25 Sensor Failure, One or One Sensor: Both Sensors: 4, 9 TS-28
Both Sensors <300, >11,500 rpm <300, >11,500 rpm
XN25 A/B Sensor Mismatch |A-B|>100 rpm TS-28
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No XN25 Indication 37 TS-28
XN25 Failure to Reach Core X XN25 <6,050 TS-25
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
Idle Speed on Start rpm, XN25R
(Hung Start) <6,400 rpm at
t>120 sec
GE Industrial AeroDerivative Gas Turbines
LM6000 PC
HPC System (Continued)
Step Decel to
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
LM6000 PC
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
XN25 Failure to Reach Fuel X For Gas Fuel: TS-25
and Ignition Speed on Start <1,700 rpm at
t>20 sec
For Liquid Fuel:
<1,200 rpm at
t>20 sec
No Start 37 TS-25
XN25 Failure to Reach <4,600 rpm at TS-25
Starter Cutout Speed t> 90 sec
GE Industrial AeroDerivative Gas Turbines
Idle Speed Too High or Too 37 TS-20
Low (XN25)
Idle Speed Instability 37 TS-20
Accel to Maximum Power 37 TS-20
(XN25) Not Possible
Slow accel to Maximum 37 TS-11
Power with High or Low T48
XN25 Overspeed X >10,711 TS-21
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Volume I
GEK 105059
10-21
LPC System
10-22
Step Decel to
Volume I
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
GEK 105059
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
T2 A/B Difference Over Limit > 18°F TS-27
(10°C)
T2 Sensor Failure One Element: Both Elements: 4, 11, 18 TS-27
<-40°, >140°F <-40°, >140°F
Change 6
(<-40°, >60°C) (<-40°, >60°C)
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LPT System
Step Decel to
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
LM6000 PC
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
Post-Shutdown Fire 37 TS-2
T48 Temperature Average X >1,850°F >1,750°F 23 TS-11
(T48 Avg) Over Limit (>1,010°C) (>954°C)
Hot Start: T48 Start X T48 >schedule 22, 23 TS-1
Temperature Over Limit + 200°F (93°C)
for >3 sec
Hot Start: T48 Over Backup Limits Exceeded TS-1
Schedule Limit SPAM
GE Industrial AeroDerivative Gas Turbines
Hot Start: T48 High After T48 >schedule 37 TS-1
Lightoff + 200°F (93°C)
for >3 sec
T48 Temperature Average X <400°F (<204°C) 23 TS-11
(T48 Avg) Under Limit After Last T48 Reading
>400°F (>204°C)
T48 Reads Low/High 37 TS-2
Decreases or Goes Negative
During Lightoff
Failure to Fire: Gas Fuel X T48 <400°F 22, 23 TS-25
Start (<204°C) at t=
10 sec
Failure to Fire: Liquid Fuel X T48 <400°F TS-25
Start (<204°C) at t=
20 sec
Loss of Any Four T48 X <400°, >2,000°F 24 TS-11
Probes or Loss of Three (<204°, >1,093°C)
Adjacent T48 Probes (Loss
of T48 Avg)
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Loss of Any Individual T48 <350°, >2,000°F 24, 25, TS-11
Probe (<177°, >1,093°C) 26, 27, 28
Change 6
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High T48 Spread T48 Spread 225°F 24, 25, TS-11
(125°C) at XN25 26, 27, 28
>9,000 RPM
Volume I
GEK 105059
10-23
LPT System (Continued)
10-24
Step Decel to
Volume I
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
GEK 105059
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
T48 Overshoot or 37 TS-11
Fluctuation at High-Power
Steady-State
XNSD Sensor Failure One Sensor: Both Sensors: 4, 20 TS-28
Change 6
<350, >4,500 rpm <350, >4,500 rpm
XNSD Sensor Mismatch |A-B|>40 rpm 17 TS-21
XNSD Overspeed X >4,300 rpm 19 TS-21
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Lube System
Step Decel to
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
LM6000 PC
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
Chip Detector Alert <100 Ohms TS-13
(Any Sump, TGB Assy) >2.5 sec
Chip Detector Failure <0, >10k Ohms 37 TS-13
Oil Contamination or High 37 TS-18
Lube Level
High Oil Consumption 37 TS-18
Lube Scavenge, Lube >20 psid (>138 kPa) 19 TS-12
Supply, or VG Filter Diff.
GE Industrial AeroDerivative Gas Turbines
Pressure High (Impending
Bypass)
Lube Scavenge Overtemp >300°F >340°F TS-14
(Any sump, TGB Assy) (>149°C) (>171°C)
Lube Scavenge Overtemp >240°F >265°F TS-14
(AGB) (>115°C) (>129°C)
Lube Scavenge Overtemp >285°F >310°F TS-14
(A/TGB) (>140°C) (>154°C)
Lube Scavenge Overtemp >305°F >330°F TS-14
(B-Sump) (>151°C) (>165°C)
Lube Scavenge Overtemp >320°F >340°F TS-14
(C-Sump) (>159°C) (>171°C)
Lube Scavenge Overtemp >290°F >315°F TS-14
(D-Sump) (>143°C) (>157°C)
Lube Scavenge Overtemp >290°F >315°F TS-14
(E-Sump) (>143°C) (>157°C)
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Fluctuating Lube Scavenge 37 TS-14
Temp
Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
Lube Scavenge or Supply One Element: Both Elements: 4, 18 TS-27
Temp, Sensor Failure, Any <-40°, >380°F <-40°, >380°F
Sensor (Any Sump, TGB (-40°, >193°C) (-40°, >193°C)
Assy)
Volume I
GEK 105059
10-25
Lube System (Continued)
10-26
Step Decel to
Volume I
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
GEK 105059
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
Lube Scavenge, Lube <0, >50 psid 19 SPAM
Supply, or VG Filter Diff. (<0, >345 kPa)
Pressure Sensor Failure
Lube Scavenge Pressure >100 psig TS-15
Change 6
High (>689 kPa) SPAM
Lube Scavenge Pressure <0, >150 psig SPAM
Sensor Failure (<0, >1,034 kPa)
Lube Supply >170°F TS-16
Overtemperature (>77°C) SPAM
Lube Supply Pressure High TS-17
See figure 8-1 for Typical Oil SPAM
Supply Pressure
Lube Supply Pressure Low X <6 psig (<41 kPa) at <15 psig at XN25 9 TS-17
(With/Without Fluctuation) 4,500-7,800 rpm >7,800 rpm SPAM
Normal Lube Oil Pressure 37 TS-17
With Fluctuations >±5 psi
No Oil Pressure 37 TS-17
Lube Supply Pressure X <0, >100 psig 9 SPAM
Sensor Failure (<0, 689 kPa)
Lube Supply Temp Sensor One Sensor: Both Sensors: 4 TS-27
Failure <-40°, 380°F -40°, 380°F
(<-40°, 193°C) (<-40°, 193°C)
Lube Supply Temp Below <90°F (<32°C) at TS-16
Minimum XN25 >6,050 rpm
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GE Industrial AeroDerivative Gas Turbines
LM6000 PC
Steam System
Step Decel to
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
LM6000 PC
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
Steam Flow Sensor Failure <0, >50,000 pph Position >Schedule SPAM
<0, >22,680 kg/h) +25 psi for
>10 sec
Steam Flow Rate High 22 TS-30
Steam Flow Rate Low 22, 32 SPAM
Steam Pressure Sensor X <0, >900 psia 12 SPAM
Failure (<0, >6,205 kPa)
Steam Pressure Over Alarm/ >700 psia 33 SPAM
GE Industrial AeroDerivative Gas Turbines
Valve Limit (>4,826 kPa)
Steam Superheat Low at X Superheat <50°F 12, 33, SPAM
Max limit/Superheat (<28°C) or Manifold 34
Temperature
>1,000°F (>538°C)
Steam Temp. Sensor X <40°, >1,200°F SPAM
Failure, Any Sensor (4°, >649°C)
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
Volume I
GEK 105059
10-27
Thrust Balance Valve System
10-28
Step Decel to
Volume I
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
GEK 105059
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
PTB Demand Error Position >Schedule Position >Schedule Position >Schedule 22 TS-30
+15 psi for >10 sec +50 psi for >1.0 sec +25 psi for >10 sec
or
>Schedule +25 psi
for >2.0 sec
Change 6
PTB Demand Check Position >Schedule Position >Schedule 22 TS-30
+25 psi for >5.0 sec +50 psi for >2.0 sec
PTB and PTBV Sensor |PTB-PTBV|> 15 psi for |PTB-PTBV|> 25 psi for TS-30
Difference 5.0 sec 2.0 sec
P48 Sensor Failure X <10, >140 psia 30 TS-30
(<69, >966 kPa)
PTB Sensor Failure X <10, >140 psia 30 TS-30
(69>966 kPa)
Thrust Balance Valve LVDT One Sensor: Both Sensors: 4, 7, 37 TS-30
Failure <-2, >102% <-2, >102%
Thrust Balance Valve LVDT >3% of stroke 16 TS-30
Difference
Thrust Balance Valve Position schedule for Demanded/Actual Diff. 7, 22 TS-30
Position Error >1.0 second and >10% for
dXN25/dt <±150 rpm/ >500 msec
sec
Thrust Balance Torquemotor X Open or short 7 TS-30
Failure >500 msec
Thrust Balance Null Current >null +/-5mA for 5.0 >null +/-15mA for 5.0 TS-30
Shift sec and dXN25/dt sec and dXN25/dt <+/-
<+/-150 rpm 150 rpm
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GE Industrial AeroDerivative Gas Turbines
LM6000 PC
Thrust Balance Orifice System
Step Decel to
LM6000 PC
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
P48 Sensor Failure X <10, >140 psia 7 SPAM
(<69, >966 kPa)
PTB Sensor Failure X <10, >280 psia 7 SPAM
(<69, >1,931 kPa)
Bearing Load-Upper Limit X TS-30A
Bearing Load-Lower Limit X TS-30A
T2 Sensor Failure One Element Both Elements 4, 11, 18 TS-27
GE Industrial AeroDerivative Gas Turbines
<-40°, >140°F <-40°, >140°F
(<-40°, >60°C) (<-40°, >60°C)
PS3 Sensor Failure, <10, >480 psia 4, 10 SPAM
One or Both Sensors (<69, >3,309 kPa)
P25 Sensor Failure <10, >40 psia SPAM
(<69, >276 kPa)
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
Volume I
GEK 105059
10-29
Variable Geometry Systems
10-30
Step Decel to
Volume I
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
GEK 105059
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
VBV A/B Difference Out of LVDT A/B difference 15 TS-23
Limits >9% of stroke
VBV LVDT - Short or Open in X TS-23
Secondary Windings
Change 6
VBV LVDT Failure One Sensor: Both Sensors: 4, 7, 21, TS-23
<-2%, >102% (if XN25 rpm) 22
<-2%, >102%
VBV Position Error X Demanded/Actual Diff. 7, 21, 22 TS-23
>10% for >0.5 sec
VBV Schedule Limits Position >Schedule 21, 22 TS-23
Exceeded for >1.0 sec and
dXN25/dt <+/-150
rpm/sec
VBV Torquemotor Failure X Open or short 7 TS-23
>0.5 sec
VIGV A/B Difference Out of LVDT A/B Difference 16 TS-23
Limits >3.0% of stroke
VIGV LVDT - Short or Open X TS-23
in Secondary Windings
VIGV LVDT Failure One Sensor: Both Sensors: 4, 7, 21, TS-23
<-2%, >102% <-2%, >102% 22
VIGV Position Error X Demanded/Actual 7, 21, 22 TS-23
Diff. >10% for
>0.5 sec
VIGV Schedule Limits Position >Schedule 21, 22 TS-23
Exceeded for >1.0 sec and
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
dXN25/DT <150 rpm/
sec
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
VIGV Torquemotor Failure X Open or short 7 TS-23
>0.5 sec
GE Industrial AeroDerivative Gas Turbines
LM6000 PC
Variable Geometry Systems (Continued)
Step Decel to
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
LM6000 PC
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
VSV A/B Difference Out of LVDT A/B difference 16 TS-23
Limits >3.7% of stroke
VSV LVDT - Short or Open in X TS-23
Secondary Windings
VSV LVDT Failure One Sensor: Both Sensors: 4, 7, 21, TS-23
<-2%, >102% (if XN25 rpm) 22
<-2%, >102%
VSV Position Error X Demanded/Actual 7, 21, 22 TS-23
Diff.>10% for >0.5
GE Industrial AeroDerivative Gas Turbines
sec
VSV Schedule Limits Position >schedule 21, 22 TS-23
Exceeded for >1.0 sec and
dXN25/dt >+/-150
rpm/sec
VSV Torquemotor Failure X Open or Short 7 TS-23
>0.5 sec
Null Current Shift +/-5mA +/-15mA TS-23 (see position
(all Variable Geometry) error)
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
Volume I
GEK 105059
10-31
Vibration Monitoring System
10-32
Step Decel to
Volume I
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
GEK 105059
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
Vibes High, HP Rotor >2.0 in/sec (>5.1 cm/ >3.0 in/sec (>7.6 cm/ TS-26
sec) at 100-200 Hz sec) at 100-200 Hz
(Tracked Core (Tracked Core
Speed) for 4 sec Speed)
Change 6
Vibes High, LP Rotor >1.4 in/sec (3.6 cm/ >2.0 in/sec (5.1cm/ TS-26
sec) peak at sec) peak at
N2ROTOR < 3,000 N2ROTOR < 3,000
or N2ROTOR ≥ 3,580 or N2ROTOR ≥ 3,590
or N25SEL ≥ or N25SEL ≥
N25MAX for 60 min N25MAX
or or
>1.75 in/sec (4.45 >2.5 in/sec (6.35 cm/
cm/sec) peak at sec) peak at 3,000 ≤
3,000 ≤ N2ROTOR < N2ROTOR < 3,590
3,580 and N25SEL < and N25SEL <
N25MAX for 4 sec N25MAX
High Wideband Rotor >3.0 in/sec >4.0 in/sec TS-26
Vibrations (7.6 cm/sec) (10.2 cm/sec)
peak at 25-350 Hz peak at 25-350 Hz
for 10 sec
Water System
Step Decel to
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
Water/Fuel Ratio High, Gas SPAM 35 TS-33
or Liquid Fuel SPAM
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
GE Industrial AeroDerivative Gas Turbines
LM6000 PC
Miscellaneous
Step Decel to
Shutdown or Core–Idle,
Emergency Shutdown Slow Decel to Troubleshooting
LM6000 PC
System/Event Alarm Shutdown 10 Seconds Later Minimum Load Abort Start Notes Reference
The events listed in this section are conditions that are not specifically handled by the engine control system or which are not part of any of the specific engine or package
systems shown previously in the table. These events are either a single symptom or combination of symptoms with no specific set of setpoints that can be monitored by the
control. These events and conditions must be monitored by the operator and corrected as they occur.
The combinations of conditions shown in this section do not cause any sort of alarm or control action to be initiated; however, individual symptoms that are part of any of the
combinations shown here may cause an alarm or control action, just as they normally would when occurring alone (such as low pressure).
Loss of Performance 37 TS-31
High HP Rotor Speed, Low 37 TS-31
Power, and High or Low T48
Engine Fails to Motor/No 37 TS-31
GE Industrial AeroDerivative Gas Turbines
Indication of Motoring
Post-Shutdown Fire 37 TS-2
Random Shutdowns or 37 TS-31
Failure to Start
High CO or Unburned 37 TS-32
Hydrocarbons
High NOx 37 TS-32
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
Volume I
GEK 105059
10-33
Notes
10-34
1. dPi is defined as the FOD screen pressure drop (dP) value measured at site commissioning.
Volume I
2. Tsv designations Saturated Vapor Temperature of gas fuel.
GEK 105059
3. Flameout signal is ignored by the control if XN25 is greater than 9,500 rpm; if a flameout has actually occurred, the loss–
of–flame logic will initiate a shutdown when XN25 drops below the 9,500 rpm threshold and a delay of 320 msec.
4. Control system defaults to remaining sensor/element.
Change 6
5. Defaults to fully closed, zero fuel flow position.
6. Defaults to site ambient during start.
7. Torquemotor current is set to zero.
8. Defaults to 665 psia (4,585 kPa).
9. Fuel and NOx valves off, VBV to kicker schedule.
10. Core VIGV torquemotor current defaults to 0mA (VIGVs closed).
11. Control system defaults to T2 = 60°F (16°C).
12. Steam valves must be closed if alarm occurs.
13. Defaults to T25 = 200°F (93°C) if both sensors fail.
14. Defaults to 1,050°F (566°C).
15. Defaults to higher signal (more closed position).
16. Defaults to higher signal (more open position).
17. Sensor loss overridden if XN25R.
18. Contact the packager if optional redundant temperature sensors (four elements per parameter) are used.
19. Alarm limits are based on component capability and may be reduced, consistent with the characteristics of each installation.
For application and site conditions that have the potential for reaching alarm limits under normal load conditions, active
controls must be available to limit fuel flow before operating limits are exceeded.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
20. This alarm/shutdown is enabled 60 seconds after reaching core idle during the starting sequence.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
21. Shutdowns caused by stall detection or variable geometry system faults require borescope inspection of the compressors.
Refer to Volume II of this manual for inspection procedures.
GE Industrial AeroDerivative Gas Turbines
LM6000 PC
Notes (Continued)
22. Refer to the appropriate packager’s manual for control schedules, logic, and limits.
23. T48 is the average of individual T48 probe outputs, subject to rejection criteria of Note 25.
LM6000 PC
24. Limits shown are for the two individual signals from any of the eight probes, as specified.
25. Any T48 thermocouple probe reading is rejected from the T48 average calculation if it is:
(1) out of range; T48 <400°F (204°C) or >1,900°F (>1,038°C)
(2) -200°F (128°C) or more below the average; T48 ≤ T48 -200°F (111°C).
26. Reject from spread calculations any thermocouple probe reading that is out of range.
27. These limits apply only at steady state conditions above 9,000 rpm XN25 or 15,000 shp output.
28. Alarm is triggered only if the condition persists for 10 seconds or more after initial detection.
GE Industrial AeroDerivative Gas Turbines
29. Twp is defined as wax point temperature for liquid fuel.
30. Liquid fuel pump inlet requirements apply only to the optional GE M&I-supplied pump. Purchaser-supplied pump require-
ments may vary.
31. Applicable to dual-fuel and gas/water fuel systems only.
32. Prolonged operation at steady state with low steam supply flows is not acceptable. Transients below this flow rate at steam
initiation are acceptable.
33. Steam pressure and temperature must be measured at the gas turbine manifold inlet.
34. Steam shutoff valves are not to be opened until the steam system has been purged of water and preheated to at least 50°F
(10°C) above steam saturation temperature. Steam injection must be secured if superheat decreases below 50°F (10°C).
35. Contact packager if application requirements dictate high water/fuel ratio.
36. LPR conditions are assessed by use of the highest speed signal from the four speed sensors (XN2a, XN2b, XNSDa,
XNSDb).
37. This condition or combination of conditions requires operator intervention, but does not, by itself, cause the control system
to initiate any sort of action.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
Volume I
GEK 105059
10-35
GEK 105059 LM6000 PC
Volume I GE Industrial AeroDerivative Gas Turbines
10-5 Troubleshooting Procedures
TS-1: Hot Start
Symptoms Possible Causes Troubleshooting Corrective Action
Starting stall; slow T48 Excess starting fuel flow SPAM: check calibration
increase plus XN25 hangup of fuel flow
or dropoff
T48 high after lightoff and Acceleration fuel flows SPAM: check PS3 sensor
during first portion of start too high or too low system
cycle VSVs off schedule TS-23
T48 start temperature over
limit VIGVs off schedule TS-23
T48 start temperature over
backup start schedule limit VBVs off schedule TS-23
NOTE Also see TS-9 for HPT/HPT degradation Borescope engine per Replace engine if out of
starting stalls WP 4015 00 specified limits
Dirty compressor Borescope engine per Water-wash engine per
WP 4015 00 WP 4014 00
Fuel metering valve SPAM
supply pressure
exceeds upper/lower
limits
Starter cutout speed too SPAM
low
Starter air/gas/hydraulic TS-25
supply pressure too low SPAM: check starter
system
Fuel nozzle failure Inspect fuel nozzles Repair or replace as
required per
WP 1510 00
Any of the above Perform engine Replace engine if out of
overtemperature specified limits
inspection per
WP 4026 00
10-1
10-36 Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume I
TS-2: Post-Shutdown Fire
Symptoms Possible Causes Troubleshooting Corrective Action
T48 rise during normal Leaking fuel shutoff SPAM: close valves, one Turn fuel off
shutdown valve(s) at a time, to isolate faulty Motor engine as
T48 >1,000°F (>538°C) valve required to blow out fire
after shutdown Motor gas generator
with starter and ignition
off until T48 indicates
400°F (204°C) or less.
Do not exceed starter
duty cycle
Replace valves as
required
Borescope HPT per
WP 4015 00 if T48
exceeds 1,000°F
(538°C)
Sensor system failure TS-27
TS-3: Inlet Screen Differential Pressure
Symptoms Possible Causes Troubleshooting Corrective Action
Pressure high Inlet screen clogged Inspect inlet screen Clean screen
with dirt or debris Replace nylon sock
Inlet screen restricted Inspect inlet screen Deice screen; provide
by ice anti-icing
Reduce power until
screen is free of ice
NOTE If any debris
has passed through or
around the screen,
remove the debris and
inspect the engine
inlet for possible
damage. Also, bores-
cope the HPC and
LPC for possible
damage per
WP 4015 00
Sensor system failure Sensor failure SPAM
Change 6 10-37
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume I GE Industrial AeroDerivative Gas Turbines
TS-4: Flameout
Symptoms Possible Causes Troubleshooting Corrective Action
Flame loss, XN25 >9,500 Sensor system failure TS-29
rpm SPAM
Flame loss, XN25 >9,500
rpm Low or no fuel flow or SPAM: check fuel system Clean/replace as
fuel pressure SPAM: check PS3 sensor required
system
VG system off schedule Check T2 sensor system;
TS-27
Check all VG system
linkages
SPAM: troubleshoot
control
Fuel metering valve SPAM
(FMV) failure
Staging valves failed TS-7
open
Bleed valves failed TS-8
close
Water system failure to SPAM: Check drain Maintain water circuit
drain following water system for water drain drain system
system shutdown valve malfunction or
obstructions
TS-5: Power Supply Failure
Symptoms Possible Causes Troubleshooting Corrective Action
No control indications Electrical power supply Inspect engine for loose SPAM: repair/replace
loss piping/joints that may power supply as
have been jarred loose if required
high-power stall occurred
Engine shutdown with Component failure in TS-9 if stall occurred
possible stall power supply SPAM
10-38 Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume I
TS-6: Fuel Supply Temperature
Symptoms Possible Causes Troubleshooting Corrective Action
Gas fuel below Tsv limit Sensor system failure SPAM SPAM: inspect fuel
metering valve for
hydrates
Liquid fuel below Twp limit Preheater system If abnormal starting or Replace flow-divider
failure T48 temperatures are valve per WP 1914 00
observed for liquid fuel, Inspect fuel-metering
the liquid flow divider valve for contamination
valve may be
contaminated by fuel
precipitate
SPAM
Fuel supply temperature Sensor system failure If temperature exceeds SPAM
high Fuel cooler system 700°F (371°C), fuel Replace hoses and
failure system hose life may be other temperature-
affected sensitive fuel system
SPAM components per
appropriate work
package
TS-7: Liquid Fuel Filter Differential Pressure
Symptoms Possible Causes Troubleshooting Corrective Action
Pressure High Contaminated Filter Remove and inspect filter Replace filter per
element Determine and correct WP 4010 00
source or cause of NOTE If filter has
contamination gone into bypass,
SPAM
inspect and clean
downstream fuel sys-
tem components
Sensor Failure Sensor system failure SPAM
No pressure indication at Sensor system failure Compare readings with Locate and correct the
XN25 >8,000 rpm Filter in bypass mode previous good data source of contamination
Missing filter element SPAM Clean and flush
downstream
components
SPAM
Change 6 10-39
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume I GE Industrial AeroDerivative Gas Turbines
TS-8: Liquid Fuel/Water Manifold Temperature
Symptoms Possible Causes Troubleshooting Corrective Action
High temperature High water or liquid fuel SPAM: if temperature Replace hoses,
supply temperature reaches 700°F (371°C) manifolds, fuel nozzles,
limit, inspect hoses and and seals per
piping for signs of appropriate work
discoloration and burning package, as required
Overtemperature Purge system failure Inspect and replace fuel
and reingestion of system components per
combustion gases appropriate work
package, as required
Inspect and replace
purge system valves
and controls per
appropriate work
package, as required
Sensor system failure Sensor failure, both TS-27
sensors
TS-9: Stall
Symptoms Possible Causes Troubleshooting Corrective Action
NOTE A starting stall is characterized by a hung start, slow acceleration to idle, lower than
normal fuel manifold pressure (or fuel flow), and higher than normal power turbine inlet temper-
ature (T48). Occasionally, the stall will continue at idle power. A stall at idle can be recognized
by one or a combination of any of the following symptoms: higher than normal T48, higher than
normal fuel manifold pressure, or XN25 does not increase or is sluggish when power is advanced
from idle.
Stall Borescope engine per Replace engine if out of
Starting stall WP 4015 00 borescope inspection
limits
VG system(s) off Inspect VSVs, VIGVs, CAUTION Bores-
schedule and VBVs check rigging cope engine before
per WP’s 1411 00, water-washing.
1113 00, and 1312 00
Washing before bore-
TS-23
SPAM (Control System) scope may cause
additional damage if
FOD already exists
Check VG pump Replace VG pump per
WP 1812 00
Control system failure SPAM
Starting system failure TS-25
10-40 Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume I
TS-9: Stall (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
Stall FOD Borescope engine per Replace engine if out of
Starting stall (cont'd) WP 4015 00 limits
Determine source of FOD CAUTION Bores-
Inspect inlet system per cope engine before
WP 4010 00
water-washing.
Washing before bore-
scope may cause
additional damage if
FOD already exists
Binding or loose VIGV Check linkages Replace parts as
or VSV linkage required per
WPs 2412 00 and
2413 00
Ice on inlet screen Inspect inlet screen Activate deicing system
Inspect engine for Melt ice with portable
damage from ice on heater
VIGVs Repair compressor if
Borescope engine for ice damage is within
damage per WP 4015 00 acceptable limits
Replace engine if out of
borescope inspection
limits
Inlet restricted by Remove obstructions; if Repair compressor or
foreign objects other screen integrity has been replace engine if FOD
than ice damaged or if there is a exceeds repair limits
possibility that objects Clean inlet and collector
have passed through the
screen into the
compressor, borescope
the engine for FOD per
WP 4015 00
High or low fuel TS-22
manifold pressure
Dirty compressor Inspect inlet per Water-wash engine per
WP 4010 00 WP 4014 00
Borescope HPC per
WP 4015 00
Unknown All of the above If all procedures above
TS-1 fail to show the cause of
the problem, the engine
must be replaced
Change 6 10-41
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume I GE Industrial AeroDerivative Gas Turbines
TS-10: T3 (High Pressure Compressor Discharge Temperature)
Symptoms Possible Causes Troubleshooting Corrective Action
High/over limits Dirty HPC Inspect inlet per Water-wash engine per
WP 4010 00 WP 4014 00
Borescope HPC per
WP 4015 00
Damaged HPC Borescope engine per Repair or replace
WP 4015 00 engine as required
Control system failure SPAM: check to see if SPAM: replace T3
engine is operating on sensor as required per
PS3 on a hot day WP 1517 00
A/B difference over limit Sensor system failure TS-27
Sensor failure
TS-11: T48 (Low Pressure Turbine Inlet Temperature)
Symptoms Possible Causes Troubleshooting Corrective Action
T48 average over limit Sensor system failure TS-27
Single probe temp over
limit Fuel nozzle failure Determine hot or cold T48 Repair or replace, as
Over spread limits based on known good required, per
T48 profile (figure 10-3). WP 1510 00. If hot T48,
Determine suspect fuel borescope HPT per
nozzles based on WP 4015 00
figure 10-4
Flow-divider valve Check flow-divider valve Replace per
failure WP 1914 00
HPT degradation Borescope HPC and HPT
per WP 4015 00
Fuel supply pressure SPAM
low (starting only)
Excess fuel flow
(starting only)
T48 average under limit Flameout TS-4
SPAM
Sensor system failure TS-27
Loss of average reading Sensor failure TS-27
Loss of any individual
probe Turbine rotor and/or Borescope turbine per
Loss of three adjacent stator damage WP 4015 00
probes
Loss of any four probes
10-42 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-11: T48 (Low Pressure Turbine Inlet Temperature) (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
Higher T48 reading than VG system off schedule Check VG systems per
previous reading at 100% WPs 1411 00, 1113 00,
power under same 1312 00, and 1313 00
operating conditions; all SPAM
other parameters changed
with T48 T2 sensor failure TS-27
Dirty compressor Inspect inlet per Water-wash engine per
WP 4010 00 WP 4014 00
Borescope HPC per Repair/replace as
WP 4015 00 required
FOD Borescope engine per Repair/replace as
Hot section WP 4015 00 required
deterioration
T48 overshoot or Sensor system or TS-27
fluctuation at high power indicator failure SPAM
steady-state
Fuel supply system Check fuel pressure SPAM
failure
Clogged fuel filter TS-7
Worn or unstable fuel SPAM
metering valve
TS-12: Lube Supply/Scavenge and VG Hydraulic Filter Differential Pressure
Symptoms Possible Causes Troubleshooting Corrective Action
High differential pressure Contaminated filter Inspect filter Clean/replace filter
element element as required (for
VG pump/HCU filter,
see WP 4021 00)
Locate source of Correct source of
contamination contamination
SPAM
Check pump screens per
WP 4020 00
Check chip detectors per TS-13
WP 4017 00
Sensor failure: pressure Sensor system failure SPAM
less than zero or over
sensor limits
Change 6 10-43
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Volume I GE Industrial AeroDerivative Gas Turbines
TS-13: Chip Detector
Symptoms Possible Causes Troubleshooting Corrective Action
Chip detector alert Sensor system failure Check chip detector per Replace chip detector
WP 4017 00 per WP 1910 00 as
SPAM required
Engine bearing failure Check all scavenge Flush lube and
screens, chip detectors, hydraulic systems
and system filters for Replace engine as
debris (bearing debris required
plus increased engine
vibration) per
WPs 4017 00, 4020 00,
and 4021 00
Lube or VG hydraulic Check lube and hydraulic Flush lube and
pump failure screens and system filters hydraulic systems
for debris per Replace defective VG
WPs 4020 00 and or lube/scavenge pump
4021 00 per WP 1812 00 or WP
1813 00, as required
Chip detector failure Sensor system failure Check chip detector per Replace chip detector
WP 4017 00 per WP 1910 00 as
Clean chip detector required
SPAM
10-44 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-14: Lube Scavenge Temperature
Symptoms Possible Causes Troubleshooting Corrective Action
Overtemperature: dark oil Low oil level in lube Check oil level Drain, flush clean, and
in tank samples; burned tank service tube/hydraulic
odor; sludge and varnish system and all filters
on oil filter; sludge on chip Clean chip detector as
detector required per SPAM
Refill tanks to correct
level; monitor scavenge
temperature when
operation resumes
Low oil flow in sumps Flow-check supply jets Replace engine as
per WP 4027 00 required
Check lube/scavenge Replace pump per
pump discharge pressure WP 1813 00 as
required
Check filter Clean/replace oil filter
as required
Scavenge pump inlet Clean scavenge pump
screens clogged inlet screens per
WP 4020 00
Determine and
eliminate cause of
contamination
High oil supply TS-16 SPAM
temperature
Sump air/oil seal failure Check individual sump Repair or replace
temperatures to isolate engine as required
area of failure
Bearing failure Check individual chip Replace modules or
detectors and lube and engines as required.
scavenge pump screens
per WP 4017 00 and
WP 4020 00.
Fluctuating lube scavenge Sensor system failure TS-27
temperature
Control valve cycling SPAM
Fluctuating lube supply SPAM
temperature
Change 6 10-45
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Volume I GE Industrial AeroDerivative Gas Turbines
TS-15: Lube Scavenge Pressure
Symptoms Possible Causes Troubleshooting Corrective Action
High pressure Lube scavenge filter Check lube and scavenge Replace filter as
contaminated filter per WP 4020 00 required
SPAM Determine and correct
cause of contamination
Piping, check valve, SPAM SPAM
heat exchanger, or
other components
between lube and
scavenge pump outlet
and oil tank are too
restrictive due to
contamination or failure
Cold oil Warm oil with heater or
by operating engine
Sensor Failure Sensor system failure SPAM
TS-16: Lube Supply Temperature
Symptoms Possible Causes Troubleshooting Corrective Action
Overtemperature Oil cooler fouled SPAM
Improper oil cooler
temperature control
High lube scavenge oil TS-14
temperature
Below minimum Lube heater failure SPAM
Sensor failure Sensor system failure TS-27
SPAM
10-46 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-17: Lube Supply Pressure
Symptoms Possible Causes Troubleshooting Corrective Action
High pressure Low oil temperature Run engine long enough
CAUTION Do not to warm oil
operate engine if oil SPAM: check operation of
lube oil cooler and/or lube
pressure is more than 30
tank heater
psig (206.8 kpa) above
normal after engine Sensor system failure SPAM
reaches stabilized tem- Oil line blockage or kink Check for crimped or Replace or clean oil
perature. Continued blocked oil supply tubes lines as required
operation under these downstream of pressure
conditions may damage tap
the engine SPAM
Clogged oil lines and Monitor scavenge oil Clean oil lines
jets, often indicated by temperature and record (Pulling vacuum is one
tendency of pressure to any abnormal acceptable method)
creep upward temperature to isolate Replace engine
problem area. Check all
chip detectors and record
locations of chips before
replacing engine Flow-
test bearing sumps per
WP 4027 00
Low pressure with Low oil tank level SPAM
fluctuation
Oil leak Check external Replace leaking
components for leakage components
Check torque on all oil Retighten all loose
lines fittings
Sensor failure SPAM
Oil/water contamination Check oil sample for milky SPAM
appearance or for dilution Repair source of water
with water. Isolate and entry into tank. Drain,
remove source of water, if flush, and refill oil
found system and clean or
replace oil filters
Lube/scavenge pump Check pump relief valve Replace lube/scavenge
relief valve failure pump per WP 1813 00
Change 6 10-47
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Volume I GE Industrial AeroDerivative Gas Turbines
TS-17: Lube Supply Pressure (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
Low pressure with Obstructed or collapsed Disconnect supply line at Replace supply line
fluctuation (cont'd) oil supply line to pump pump and check flow
Check oil-in flex hose for Replace oil-in hose
deterioration
Check for obstruction in Remove obstruction
pump inlet from pump
Replace lube/scavenge
pump per WP 1813 00,
as required
Clogged oil filter Check oil filter ΔP SPAM: service filter
Low pressure without External oil leak Inspect for large oil leaks Repair leaks
fluctuation
Internal oil leak Check for high oil Repair or replace
(possible damage to oil consumption engine as required
seals)
Lube/scavenge pump Check lube or scavenge Replace lube/scavenge
failure discharge for oil flow pump per WP 1813 00
Sensor system failure SPAM
Normal lube oil pressure Low oil tank level SPAM
with fluctuations > ±5 psi
Oil/water contamination Check oil sample for milky Repair source of water
NOTE Oil pressure
appearance or for dilution entry into oil tank. Drain,
fluctuation during tran- with water flush, and refill oil
sients is considered nor- system with fresh oil.
mal; however, the Clean or replace oil
fluctuations should stop filters
within 1 minute after a Clogged filter Check oil filter ΔP SPAM
steady-state condition is
established Sensor system failure SPAM
Blocked or defective Check pump screen per
pump inlet line WP 4020 00
SPAM
Defective lube/ Replace lube/scavenge
scavenge pump relief pump per WP 1813 00
valve as required
Defective oil tank vent SPAM
Air in system lines Run engine to purge air
10-48 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-17: Lube Supply Pressure (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
No oil pressure Sheared pump shaft Check for XN25 indication Replace pump if XN25
while motoring engine indication is present
Verify lube supply to with no oil pressure and
pump normal oil supply to
pump
Low oil tank level SPAM
Faulty oil pressure SPAM
indication; faulty
transmitter or pressure
line
Obstructed oil supply Disconnect supply line Continue
line to pump and check for presence of troubleshooting
oil
Check oil supply flex hose Replace hose
for deterioration
(collapsed or kinked)
Check for obstruction in Remove obstruction
pump inlet and clean tank
Check for improperly Correct problem
connected lines or
reversed check valve
Obstructed tank inlet Remove inlet strainer and Remove obstruction
strainer inspect for obstructions and clean oil strainer
and tank
Lube/scavenge pump Check lube or scavenge Replace lube/scavenge
failure discharge for oil flow pump per WP 1813 00
Loss of pump prime Check pump inlet line for Fill oil line with oil as
presence of oil required
Change 6 10-49
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Volume I GE Industrial AeroDerivative Gas Turbines
TS-18: Lube System - Miscellaneous
Symptoms Possible Causes Troubleshooting Corrective Action
Oil contamination Maintenance error; lube Contact GE M&I Flush lube and
tank serviced with Customer Service before hydraulic systems
contaminated oil continuing operation Completely drain oil
CAUTION If engine tank and as many
is operated for more service lines as
possible. Service with
than 200 hours with
fresh MIL-L-23699 oil
MIL-L-23699 oil con- and operate the engine
taining more than 5% for 5 minutes at core
mineral oil, significant idle. Shut down the
internal coking may engine, drain the oil
occur tank and lines, and refill
with fresh oil
Lube/scavenge or VG Check lube and hydraulic Flush lube and
pump failure screens and system filters hydraulic systems
for debris per Replace defective VG
WPs 4020 00 and or lube/scavenge pump
4021 00 per WP 1812 00 or
WP 1813 00, as
required
Engine bearing failure Check all scavenge Flush lube and
screens, chip detectors, hydraulic systems
and system filters for Replace engine as
debris (bearing debris required
plus increased engine
vibration) per
WPs 4017 00, 4020 00,
and 4021 00
Dirty engine Borescope engine per Water-wash engine per
WP 4015 00 WP 4014 00
Tighten coupling nuts or
replace defective parts
as required
Liquid fuel in lube oil Check lube to fuel heat SPAM
tank exchanger for leaks
SPAM
10-50 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-18: Lube System - Miscellaneous (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
High oil consumption Records in error Verify records Correct records
Oil leak in combined See figure 10-5 See figure 10-5
actuator drain,
combined accessory
drive pad drains,
combined drain-sumps,
starter drain, or external
lines
Oil pump seal drain See figure 10-5 See figure 10-5
leakage
TGB assembly See figure 10-5 See figure 10-5
Internal engine damage See figure 10-5 See figure 10-5
Front frame strut See figure 10-5 See figure 10-5
leakage
Air/oil separator Inspect lines and drains Clean or replace as
blockage SPAM required
Extended engine SPAM: control system SPAM
operation with no LPT
rotation
Sump pressurization Inspect tubes and vents Clean or replace as
tube or vent line required
blockage or damage
Lube pump failure Inspect pump and check Replace lube/scavenge
(flooded sump) discharge pressure pump per WP 1813 00
TS-19: XN2/LPC Speed and XNSD/LPT Speed - Not applicable to PC
Change 6 10-51
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Volume I GE Industrial AeroDerivative Gas Turbines
TS-20: XN25/HPC Speed
Symptoms Possible Causes Troubleshooting Corrective Action
Sensor mismatch Sensor system failure TS-28
No speed indication SPAM
Idle speed too high/low Stall TS-9
T2 sensor failure TS-27
Control failure SPAM
Speed sensor system TS-28
failure
Fuel metering valve SPAM
failure
Fuel system failure TS-25
Idle speed instability Water in fuel Check fuel filters SPAM
SPAM
Air in liquid fuel system Advance power and Recheck idle speed
return to idle stability
Fuel metering valve SPAM
failure
Fuel inlet pressure SPAM
fluctuation
Intermittent T25, XN25, TS-27
or PS3 sensor output TS-28
SPAM: PS3
Accel to maximum power Low fuel flow or no fuel SPAM: check SPAM
not possible flow and fuel pressure - PS3 line to sensor
- PS3 sensor circuit
- Fuel flow vs PS3
schedule
Fuel filter blocked Check fuel filters per Replace filters
WPs 4018 00 and
4019 00
VG system off schedule TS-23
Control system failure SPAM
10-52 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-21: Overspeed
Symptoms Possible Causes Troubleshooting Corrective Action
XN2 overspeed Control failure (without Perform overspeed Replace engine if
XNSD overspeed shutdown) inspection per damage exceeds limits
XN25 overspeed WP 4025 00 SPAM
SPAM
Sensor system failure TS-28
SPAM
Worn or unstable fuel SPAM
metering valve
Radial drive shaft failure Attempt manual engine Isolate and replace
rotation from defective drive
maintenance crank pad component per
on aft end of TGB Assy. WPs 2810 00, 2811 00,
View HPC rotor through or 2812 00
borescope port
(WP 4015 00) to see if
HPC rotates
High-speed coupling SPAM SPAM
shaft failure
Any of the above Perform overspeed Replace engine if
inspection per damage exceeds limits
WP 4025 00
Change 6 10-53
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Volume I GE Industrial AeroDerivative Gas Turbines
TS-22: Miscellaneous Liquid or Gas Fuel System Problems
Symptoms Possible Causes Troubleshooting Corrective Action
Shutoff valve cycling Control failure SPAM
Valve failure
Valve power failure
Fuel manifold pressure too Fuel shutoff valve SPAM
low at start failure
Fuel manifold pressure too Fuel nozzle Check fuel flow; if within Replace fuel nozzles
high or too low at power limits, check fuel nozzles per WP 1510 00 as
SPAM required
Fuel supply system SPAM
failure
Fuel metering valve Incorrect gas supply
slewing wide open during pressure
start
- Improper wiring SPAM SPAM
between valve and
control
- Improper piping SPAM SPAM
between fuel supply
and valve
10-54 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-23: Variable-Geometry Systems (VBVs, VIGVs, and VSVs)
Symptoms Possible Causes Troubleshooting Corrective Action
A/B difference out of limits LVDT sensor system Check resistance per Replace actuator per
failure table 10-1 WPs 1112 00, 1311 00,
SPAM: check or 1410 00
instrumentation and
control systems
Loose/damaged Check system linkages Adjust or replace as
actuation system for loose, missing, or required
binding hardware
Torquemotor failure LVDT sensor system Check resistance per Replace actuator per
failure table 10-1 WPs 1112 00, 1311 00,
SPAM: check or 1410 00
instrumentation and
control systems
Torquemotor/servovalve Check resistance per Replace HCU per
failure table 10-1 WP 1811 00 (servos not
SPAM: check individually replaceable)
instrumentation and
control systems
SPAM: check schedule by
motoring engine
VBVs, VIGVs, VSVs slow Control board failure. Check HCU per Replace HCU per
to actuate HCU torquemotor/servo table 10-1. Check WP 1811 00.
valve failure resistance per TS-24. SPAM
SPAM: check control
system
Position error LVDT sensor system Check resistance per Replace actuator per
Schedule limits exceeded failure table 10-1 WPs 1112 00, 1311 00,
SPAM: check or 1410 00
instrumentation and
control systems
Low or no hydraulic Check VG and HCU Clean or replace filters/
pressure system filters/screens screens as required
Check pressure at idle Replace VG pump per
WP 1812 00
Check for air in hydraulic Bleed system
system
Incorrect rigging Check rigging and VBV Correct rigging as
door seals per required
WPs 1411 00, 1113 00, Replace door seals per
1312 00, and 1313 00 WP 1313 00 as required
Change 6 10-55
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Volume I GE Industrial AeroDerivative Gas Turbines
TS-23: Variable-Geometry Systems (VBVs, VIGVs, and VSVs) (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
Position error HCU torquemotor null Check lube supply RTD Replace HCU per
Schedule limits exceeded current shift: Check drains WP 1811 00
(cont'd) - Contamination Operate with lube
- Mechanical failure temperature between
- Low/high lube oil 140°F to 160°F (59.9°C
temperature to 71.1°C)
- Leaking actuator(s) Replace actuator(s) per
WPs 1112 00, 1311 00,
or 1410 00
Short or open in secondary Sensor system or LVDT TS-24 Replace defective
windings failure SPAM actuator per
WPs 1112 00, 1311 00,
or 1410 00
Off schedule Any of the above
VIGVs too closed P0 or PS3 transducer SPAM SPAM: calibrate
calibration transducers to absolute
scale
P0 sensor line leakage Tighten fittings; blow out
or trapped fluid
TS-24: LVDTs and Torquemotors
Symptoms Possible Causes Troubleshooting Corrective Action
LVDT failure LVDT sensor failure Table 10-1 Table 10-1
Torquemotor failure Torquemotor coil failure Table 10-1 Table 10-1
10-56 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-25: Miscellaneous Starting Problems
Symptoms Possible Causes Troubleshooting Corrective Action
No start SPAM
NOTE De-energize
ignition system, place
start selector switch
in ON position, and
motor engine per
packager’s instruc-
tions to purge any fuel
vapor. Do not exceed
starter duty cycle
SPAM: check gas
properties system
PS3 and P48 sensor SPAM: trace lines or Switch lines
swapped apply pressure and check SPAM
readout at ECU
No start: XN25 and fuel Faulty ignition circuit Perform ignition system Repair or replace as
pressure OK (rpm and fuel pressure functional check per required
OK) WP 4023 00 SPAM
SPAM (wrong igniter
selected)
Incorrect fuel SPAM
Fuel metering valve SPAM: motor engine and
(FMV) minimum stop measure fuel flow (liquid)
incorrectly set
FMV failure SPAM SPAM: replace valve
Fuel system piping SPAM SPAM: eliminate leaks
leaks or restrictions and restrictions
No start: XN25 and ignition Fuel supply pressure SPAM: check vent and SPAM
OK, but low or no fuel failure drain valve positions
manifold pressure
Check fuel shutoff valve Open fuel inlet valve
position
Check fuel system SPAM: correct as
pressures required
Fuel contamination Disconnect supply lines Bleed air from fuel
and check for clogged supply lines
upstream filters or air and/ Flush contaminants
or contamination in supply from fuel supply lines
lines Clean upstream filters
Change 6 10-57
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Volume I GE Industrial AeroDerivative Gas Turbines
TS-25: Miscellaneous Starting Problems (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
No start: XN25 rises rapidly Sheared radial drive Crank engine from Isolate and replace
to starter cutout speed shaft, PTO gear, or maintenance pad on aft defective drive
input gearing end of TGB Assy. View component per
rotor through borescope WPs 2810 00, 2811 00,
port (WP 4015 00) to see and 2812 00
if HPC rotates
Failure to light off Same as above Same as above
Ignition system failure Perform ignition system Replace igniters per
functional check per WP 1516 00
WP 4023 00 SPAM
SPAM: wrong igniter
selected
10-58 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-25: Miscellaneous Starting Problems (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
Failure to reach core idle Low starter output SPAM
speed on start (hung start)
Speed sensor system TS-28
Failure to reach starter
failure SPAM
cutout speed
Failure to reach fuel and Low starter air, gas, or SPAM
ignition speed on start hydraulic pressure
NOTE The above Radial drive shaft or Check drive shaft and Service, repair, or
symptoms may be accom- starter failure starter replace starter (GE
panied by low fuel flow SPAM only) per WPs 1814 00,
and low T48 1815 00, and 4022 00
Repair or replace radial
drive per WP 2810 00
Low fuel flow or no fuel SPAM: check
flow and fuel pressure - PS3 line to sensor
- PS3 sensor circuit
- Fuel flow vs PS3
schedule
Fuel contamination Disconnect supply lines Bleed air from fuel
and check for clogged supply lines
upstream filters or air and/ Flush contaminants
or contamination in supply from fuel supply lines
lines Clean upstream filters
VG position off TS-23
schedule
Excessive compressor Borescope HPC per Replace engine
rotor rub WP 4015 00. Rolled-over
blade tips indicate heavy
rubs
HPC damage Borescope per Repair or replace
WP 4015 00 engine as required
Start stall/hot start TS-1
TS-9
Change 6 10-59
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Volume I GE Industrial AeroDerivative Gas Turbines
TS-25: Miscellaneous Starting Problems (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
No start, no XN25 Starter air, gas, or SPAM: check starter air, Increase pressure to
indication, no oil pressure hydraulic pressure gas, or hydraulic supply proper limit, or replace
below limits pressure starter if pressure is OK
Starter inoperative
Faulty starter gas, air, or SPAM: check starter gas, Restore power supply
hydraulic shutoff valve air, or hydraulic valve or replace faulty
control voltage and valve component
pressure
Faulty start selector SPAM: check start Replace switch and/or
switch or open circuit selector switch and circuit reset circuit breaker
breaker breaker
Seized engine For a cold engine, check Attempt another start
engine rotation with after cool-down period
starter or with ratchet and/or rotation check
wrench on TGB Assy Repair or replace
maintenance crank pad engine as required
For a hot engine, any
attempt to motor the
engine must be made
within 5 minutes after
shutdown. If the engine
cannot be motored within
5 minutes, wait for the
required 4-hour cooling
period before attempting
to motor again. If the
engine turns, make a
normal start. If LP rotor
does not turn by the time
the HP rotor reaches idle
speed, shut down and try
a second start. If this fails
to produce LP rotor
rotation, shut down and
investigate
Check for binding, rubs,
etc.
Borescope engine per
WP 4015 00
Check chip detectors per
WP 4017 00
10-60 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume I
TS-25: Miscellaneous Starting Problems (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
No start, no XN25 Seized engine (cont'd) Check VSV system for If vane has become
indication, no oil pressure mechanical integrity; disengaged or rotated
(cont'd) verify that there is no and has grooved the
vane rotation and that no HPC rotor, the vane
vane tip is digging into must be removed and
HPC rotor replaced. The depth of
the HPC rotor groove
must also be measured.
If the groove is through
the alumina coating, the
engine must be
replaced
Repair or replace as
required per
WPs 2411 00, 2412 00,
or 2413 00
Borescope LPC, HPC, Repair or replace as
and HPT for FOD or required per
temperature damage WPs 2411 00, 2412 00,
or 2413 00
Check cold engine Replace engine if it
rotation with ratchet cannot be made to
wrench on TGB Assy rotate with ratchet
maintenance crank pad wrench
No start, no XN25 XN25 sensor system TS-28
indication failure
Change 6 10-61
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TS-26: Engine Vibration
Symptoms Possible Causes Troubleshooting Corrective Action
High vibes, HP rotor Sensor system failure Perform functional check Repair or replace
High vibes, LP rotor per WP 4024 00 accelerometers as
SPAM required per
WP 1911 00
SPAM
Rotor imbalance: LP Check and eliminate all Balance rotor per
rotor other possibilities WP TBD
Rotor imbalance: HP Check and eliminate all Replace engine
rotor other possibilities
Engine not mounted SPAM: check engine SPAM: realign and
securely mount system tighten mounts
Bearing failure Check chip detector for Repair or replace
metal particles engine as required
Check oil scavenge inlet Repair or replace
screens for metal engine as required
particles
FOD Borescope engine per Repair or replace
WP 4015 00 engine as required
Rotor shift Determine if vibrations Replace engine as
are 1/rev for the HP rotor required
Compressor or turbine Inspect compressor inlet Repair or replace
damage area per WP 4010 00 engine as required
Borescope engine per
WP 4015 00
Dirty compressor Inspect inlet area per Water-wash engine per
WP 4010 00 WP 4014 00
Borescope HPC per
WP 4015 00
Loose sensor Inspect sensor mounting Repair or replace per
WP 1911 00
10-62 Change 6
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TS-27: Temperature Sensors
Symptoms Possible Causes Troubleshooting Corrective Action
Liquid fuel/water manifold Sensor or cabling Table 10-5, Group 1 Repair or replace as
sensor failure failure, type K Table 10-6 required per WP 1912 00
thermocouple SPAM
Signal-conditioning or SPAM
display failure
T48 - Loss of average Sensor or cabling Table 10-5, Group 2 Repair or replace as
reading failure, type K Table 10-7 required per WP 1711 00
T48 - Cold sensor thermocouple SPAM
T48 - Loss of three Signal-conditioning or SPAM
adjacent probes display failure
T48 - Loss of four probes System ground loop Table 10-5, Group 2 Repair or replace as
T48 - Loss of any probe Table 10-6 required per WP 1711 00
T48 - High or over limit SPAM SPAM
T3 sensor failure Sensor or cabling Table 10-5, Group 3 Repair or replace as
T3 A/B difference over limit failure, type K Table 10-7 required per WP 1517 00
thermocouple SPAM
Signal-conditioning or SPAM
display failure
T25 sensor failure Sensor or cabling Table 10-5, Group 4 Repair or replace as
T25 A/B difference over failure, resistance Table 10-6 required per WP 1310 00
limit temperature detector SPAM
(RTD), see table 10-7
Signal-conditioning or SPAM
display failure
T2 sensor failure Sensor or cabling Table 10-5, Group 5 Repair or replace as
T2 A/B difference over limit failure, RTD, see Table 10-6 required per WP 1111 00
table 10-7 SPAM
Signal-conditioning or SPAM
display failure
Lube supply or scavenge Sensor or cabling Table 10-5, Group 6 Repair or replace as
temperature sensor failure failure, RTD, see Table 10-6 required per WP 1817 00
table 10-8
Signal-conditioning or SPAM
display failure
T3/T48 sensors read low/ Improper wiring Use test thermocouple or SPAM: install proper wire
high, decreases or goes - KP/KN reversed trace lines from sensors
negative during light off - Copper wire used to control and verify
proper configuration
Change 6 10-63
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TS-28: Speed Sensors
Symptoms Possible Causes Troubleshooting Corrective Action
XN25 sensor failure Sensor system failure Paragraph 10-3.1 Repair or replace as
XNSD sensor failure and table 10-9 required per
XN25 sensor mismatch Check sensor, wiring, and WPs 1210 00, 1816 00,
XNSD sensor mismatch sensor installation per or 1710 00
WPs 1210 00, 1816 00,
and 1710 00
Signal-conditioning or SPAM
display failure
TS-29: Flame Sensor
Symptoms Possible Causes Troubleshooting Corrective Action
Flame loss, one sensor (no Dirty sight glass lens Inspect lenses Clean or replace per
flameout) Dirty sensor lens WP 1515 00, as
required
Sensor failure Verify operation with UV Replace sensor per
(overtemperature) light source. Verify WP 1515 00, as
temperature required
table 10-10
Wiring Check package Repair or replace as
connections from sensor required
to package signal
conditioner
Signal conditioner SPAM: check system SPAM
failure voltages
Switch sensor inputs at
the amplifier to determine
whether the problem
follows the sensor
10-64 Change 6
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TS-30: Thrust Balance Valve System
Symptoms Possible Causes Troubleshooting Corrective Action
Thrust balance pressure External line leak/ SPAM
sensors difference or obstruction
sensor failure
Internal line leak/ Replace gas turbine
obstruction
Transducer calibration/ SPAM
failure
Thrust balance pressure P0, P25, or P48 SPAM: check for leaks
demand check sensors system failure SPAM: check transducer
calibration
XN2 TS-19
T2 TS-27
VBV or VIGV TS-23
Control system failure SPAM
Thrust balance valve LVDT LVDT sensor system TS-24 Replace valve per
failure or difference failure WP 1713 00
Control system failure SPAM
Torquemotor failure or null LVDT sensor system TS-24 Replace valve per
current shift failure WP 1713 00
Torquemotor failure TS-24 Replace HCU per
WP 1713 00
Control system failure SPAM
Thrust balance valve LVDT sensor system TS-24 Replace valve per
position error failure WP 1713 00
Low or no hydraulic Check VG pump and Clean or replace filters/
pressure HCU system filters and screens as required
screens
Check for air in hydraulic Bleed system
system
Thrust balance pressure off Any of the above
schedule
Valve internal damage Change valve per
WP 1713 00
Change 6 10-65
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TS-30A: Thrust Balance Orifice System
Symptoms Possible Causes Troubleshooting Corrective Action
Thrust balance pressure P48, PTB, PS3, P25, or Check latest measured SPAM
Bearing load > upper limit T2 sensor system values versus last good
failure or calibration values or SPAM
error
P48 sensor line leakage Check latest measured Tighten or replace as
values versus last good required
values
Control system failure SPAM SPAM
Balance piston orifice is Calculate orifice size per Replace orifice per
too large or installed paragraph 10-3A WP 1714 00
incorrectly
Balance piston internal Replace engine per
running clearance is too WP 3010 00
tight
Bearing load < lower limit P48, PTB, PS3, P25, or Check latest measured SPAM
T2 sensor system values versus last good
failure or calibration values or SPAM
error
PTB sensing line Check latest measured External: Blow down
leakage or blockage values versus last good sensing lines. Replace
values or SPAM hardware or tighten
fitting as required
Internal: Replace
engine per WP 3010 00
Balance piston supply Inspect supply system Replace hardware or
system leak hardware from the tighten fittings as
eleventh stage of the high required
pressure compressor to
turbine rear frame
interface for cracked
tubes, loose fittings, or
blown gaskets
Balance piston orifice is Calculate orifice size per Replace orifice per
too small paragraph 10-3A WP 1714 00
Balance piston internal Replace engine per
running clearance is too WP 3010 00
open
10-66 Change 6
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TS-31: Miscellaneous Problems
Symptoms Possible Causes Troubleshooting Corrective Action
Reduced Power Dirty or damaged low or Trending equation, Water-wash (or hand
Use trending equations to high pressure compressor efficiency clean) and confirm
aid determination of power compressors Borescope per effectiveness with
loss, or compare power VIGVs too closed WP 4015 00 borescope inspection
output on similar inlet per WP 4014 00
condition
(P2 and T2 days)
1. Improper rig Check rigging per Rig per WP 1113 00
WP 1113 00
2. Improper con- SPAM: check calibration SPAM: calibrate VIGV
trol calibration drives
3. Mechanical Visually inspect per Determine root cause
malfunction WP 4012 00 and replace hardware
as required
4. PS3 sensor Plot P53 versus P48; Calibrate sensor to
reading too low check for leaks absolute scale;
eliminate leaks
5. P0 sensor read- Compare P0 to ambient Calibrate sensor using
ing too high pressure. P0 ~ 2 to 6 in. accurate barometric
(up-stream of water less than ambient gauge
inlet screen/ pressure
sock)
6. T2 reading too Compare to other inlet Replace sensor per
low temperatures; check WP 1111 00
resistance per table 10-7
VBVs too open (should
close by ~ 33 MW)
1. Bad T2 or XN25 Check T2 resistance per Replace sensors as
signal (2 table 10-7 required per
sensors) Check XN25 per WP 1111 00 (T2) and
table 10-9 WP 1816 00 (XN25)
2. Improper Check rigging per Rig per WP 1312 00
rigging WP 1312 00
3. Miscalibrated SPAM: control system Calibrate VBV driver
calibration
Change 6 10-67
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TS-31: Miscellaneous Problems (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
Reduced Power VSVs too closed
Use trending equations to
aid determination of power 1. Bad T25 or Check T25 resistance per Replace sensors as
loss, or compare power XN25 signal table 10-7 required per
output on similar inlet (2 sensors) Check XN25 per WP 1310 00 (T2) and
condition table 10-9 WP 1816 00 (XN25)
(P2 and T2 days) 2. Improper Check rigging per Rig per WP 1411 00
(cont'd) rigging WP 1411 00
3. Miscalibrated SPAM: control system Calibrate VBV driver
calibration
Bad T3 or T48 system
1. Individual sen- Check probes resistance Replace probes per
sor or harness per WP 1711 00 WP 1711 00
failure Check harness resistance Replace harness per
per table 10-6 (visual for WP 1913 00
broken wires)
2. Control system Input type K SPAM: calibrate control
calibration or thermocouple equivalent system or correct wiring
miswiring of 1,000°F voltage and
system confirm control readout
High inlet loss Check loss across inlet Change filters
filters
Nonrecoverable engine Borescope gas turbine Hot section or overhaul
deterioration Trending equations required
Inadequate gas Pressure differential Verify proper gas
pressure differential needs to be at least pressure
across gas fuel valve 50 psi (345 kPa) across
valve
High HP rotor speeds at VG system(s) off TS-23
high power and high or low schedule
T48
Dirty compressor Inspect inlet per Water-wash engine per
WP 4010 00 WP 4014 00
Borescope HPC per
WP 4015 00
FOD Borescope engine per Repair or replace
WP 4015 00 engine as required
10-68 Change 6
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TS-31: Miscellaneous Problems (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
Engine fails to motor, but Radial drive shaft failure Attempt manual rotation Isolate and replace
control indicates motoring; through maintenance defective drive
rapid increase in indicated crank pad on aft end of component per
motoring speed TGB Assy. View rotor WPs 2810 00, 2811 00,
through borescope port and 2812 00
(WP 4015 00) to see if
HPC rotates
Engine fails to motor/no Seized engine For cold engine, check Attempt another start
indication of motoring rotation with starter or and/or rotation check
with ratchet wrench on after cool down period
TGB Assy maintenance Repair or replace
crank pad engine as required
For a hot engine, any
attempt to motor must be
made within 5 minutes
after shutdown. If the
engine cannot be motored
within 5 minutes, wait the
required 4-hour cooling
period before attempting
again. If the engine turns,
make a normal start. If LP
rotor does not turn by the
time the HP rotor reaches
idle speed, shut down and
try a second start; if the
LP rotor still does not
rotate, shut down and
investigate
Check for binding, rubs,
etc.
Borescope engine per
WP 4015 00
Check chip detectors per
WP 4017 00
Speed sensor system TS-28 Repair or replace as
failure necessary
Low starter supply SPAM
pressure
Starter exhaust
blockage
Change 6 10-69
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TS-31: Miscellaneous Problems (Continued)
Symptoms Possible Causes Troubleshooting Corrective Action
Engine fails to motor/no Starter failure Attempt manual engine Service, repair, or
indication of motoring rotation through the replace starter per
(cont'd) gearbox; if engine rotates, WPs 1814 00, 1815 00,
the problem is in the and 4022 00 (GE starter
starter system only)
Accessory failure Remove gearbox-driven If engine will rotate after
accessories one at a time removal of an
and attempt manual accessory, replace the
engine rotation after each failed accessory
accessory is removed
Transfer gearbox failure If engine will not turn after Replace the transfer
removal of all gearbox per
accessories, remove the WP 2811 00
radial drive shaft per
WP 2810 00. Rotate the
transfer gearbox
FOD If starter and drive drain Repair or replace
operate properly, but engine as required
engine will not rotate,
borescope the engine per
WP 4015 00
Bearing or seal failure Check chip detectors for Repair or replace
debris; check sump engine as required
scavenge screen in lube
and scavenge pump for
evidence of bearing or
seal failure
Random shutdowns or Wiring ground faults SPAM: check engine to SPAM: correct shielding
failure to start control wiring for improper an/or routing of wiring.
shielding or grounding
Check for faulty control Reseat/replace circuit
circuit boards boards
High enclosure Package ventilation SPAM SPAM
temperature system failure
Broken gas turbine air Inspect external
tube configuration per
WP 4012 00
10-70 Change 6
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TS-32: Emissions
Symptoms Possible Causes Troubleshooting Corrective Action
High CO or unburned Natural gas ingested Using appropriate
hydrocarbons into inlet hydrocarbon detection
equipment, sniff for gas
around inlet
Excessive water Reduce water injection
injection and plot CO vs NOx
Incorrect emissions Use independent
measurement measurement. Check CO
versus NOx
characteristics
Duct burner Measure downstream of
gas turbine or turn off duct
burner
Combustor damage Borescope combustor per Replace engine per
WP 4015 00 WP 3010 00 or
combustor per
WP 2510 00
High NOx Insufficient water Increase water
injection injection. Normal water-
to-fuel ratio for 25 ppm
NOx, 15 percent O2, is
0.9. Water should not
be increased beyond
this level without prior
troubleshooting of the
fuel system
components. Excessive
water injection will
reduce the life of the
combustor and hot
section components
Combustor damage Borescope combustor per Replace engine per
WP 4015 00 WP 3010 00 or
combustor per
WP 2510 00
Change 6 10-71
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TS-33: Excessive Water Injection
Symptoms Possible Causes Troubleshooting Corrective Action
High CO Improper control Measure emissions at Adjust control
Excessive or abnormal water-to-fuel schedules gas turbine exhaust schedules (requires GE control
combustor deterioration technician)
Fuel metering valve SPAM: Calibrate device
(FMV) or flow meter
calibration
Improper HMI fuel lower Measure gas LHV Adjust LHV in HMI
heating value (LHV)
setting (where water is
scheduled on FMV)
Low gas fuel supply Adjust water-to-fuel control
pressure schedules (requires GE control
technician) or otherwise
increase fuel supply pressure
10-72 Change 6
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TBD
Figure 10-1 LM6000 PC Control System Component Schematic (Sheet 1 of 2)
Change 6 10-73
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TBD
Figure 10-1 LM6000 PC Control System Component Schematic (Sheet 2 of 2)
10-74 Change 6
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Figure 10-2 Engine Electrical Interface Panels
Change 6 10-75
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Figure 10-3 LM6000 PC T48 Profiles - Gas Engines
Figure 10-4 Roadmap to Troubleshooting Fuel Nozzles based on Abnormal T48
10-76 Change 6
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Figure 10-5 Troubleshooting LM6000 High Oil Consumption Due to Gas Turbine Leaks
Change 6 10-77
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Figure 10-6 InterfaceES7/E7
10-78 Change 6
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Figure 10-7 Interface ES8/E8
Change 6 10-79
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Figure 10-8 Interface ES16/E16
10-80 Change 6
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Figure 10-9 Interface ES21/E21
Change 6 10-81
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Figure 10-10 Interface ES5/E5
10-82 Change 6
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Figure 10-11 Interface ES6/E6
Change 6 10-83
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Figure 10-12 Interface ES29/E29
10-84 Change 6
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Figure 10-13 T48 Sensor and Harness Layout
Change 6 10-85
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Figure 10-14 Interface ES26/E26
10-86 Change 6
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Figure 10-15 Interfaces ES1/E1 and ES9/E9 (Standard) and ES2/E2 and ES14/E14 (Optional)
Change 6 10-87
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Figure 10-16 Interface ES19/E19
10-88 Change 6
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Figure 10-17 Interface ES20/E20
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Figure 10-18 Interface ES17/E17 (Optional)
10-90 Change 6
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Figure 10-19 Interface ES18/E18
Change 6 10-91
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Figure 10-20 Interface ES10/E10 and ES11/E11
10-92 Change 6
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Figure 10-21 Interfaces ES34/E34 and ES36/E36
Change 6 10-93
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Figure 10-22 Interfaces ES30/E30 and ES31/E31
10-94 Change 6
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Figure 10-23 Thrust Balance Valve Interface ES56/E56
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Figure 10-24 Interfaces E27 and E28
10-96 Change 6
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Figure 10-25 Interfaces ES22/E22, ES23/E23, ES32/E32, and ES35/E35
Change 6 10-97
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Figure 10-26 Interfaces ES12/E12 and ES13/E13 (Optional)
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Table 10-1 LVDT/Torquemotor Resistance Values for T48
Resistance*
(Ohms ±10%)
Reference Component Unless Corrective
Component Figure Interface Pins Specified Action
VIGV LVDT 10-6 ES7/E7 2-3 88-140 Primary Replace actuator
4-5 66-90 Sec 1 per WP 1112 00
6-7 76-112 Sec 2
VIGV LVDT 10-7 ES8/E8 2-3 88-140 Primary Replace actuator
4-5 66-90 Sec 1 per WP 1112 00
6-7 76-112 Sec 2
VBV LVDT 10-8 ES16/E16 2-3 88-140 Primary Replace actuator
4-5 66-90 Sec 1 per WP 1311 00
6-7 76-112 Sec 2
VBV LVDT 10-9 ES21/E21 2-3 88-140 Primary Replace actuator
4-5 66-90 Sec 1 per WP 1311 00
6-7 76-112 Sec 2
VSV LVDT 10-8 ES16/E16 2-3 88-140 Primary Replace actuator
4-5 66-90 Sec 1 per WP 1410 00
6-7 76-112 Sec 2
VSV LVDT 10-9 ES21/E21 2-3 88-140 Primary Replace actuator
4-5 66-90 Sec 1 per WP 1410 00
6-7 76-112 Sec 2
TBV LVDT 10-23 ES56/E56 3-4, 10-11 90 Primary Replace valve per
5-6, 12-13 70 Sec 1 WP 1713 00
6-7, 13-14 70 Sec 2
TBV LVDT 10-23 ES56/E56 10-11 90 Primary Replace valve per
12-13 70 Sec 1 WP 1713 00
13-14 70 Sec 2
VIGV T/M Coil 10-23 N/A 1-2, 8-9 40 Replace valve per
WP 1713 00
VBV T/M Coil 40
VSV T/M Coil 40
TBV T/M Coil 10-23 ES56/E56 1-2 32 (coil only)
VIGV T/M Coil 10-23 N/A 3-4, 10-11 40 Replace valve per
VBV T/M Coil 40 WP 1811 00
VSV T/M Coil 40
TBV T/M Coil 32 (coil only)
* At room temperature or as specified in tables.
Change 6 10-99
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Table 10-2 Flame Detector Resistance Values
Reference Component Resistance* Corrective
Component Figure Interface Pins (Ohms ±10%) Action
Flame Detectors 10-24 E27/E28 1-2 511 Replace flame
detectors per
WP 1515 00
* At room temperature or as specified in tables
Table 10-3 Accelerometer Resistance Values
Reference Component Resistance* Corrective
Component Figure Interface Pins (Ohms ±10%) Action
LPC/CRF/TRF 10-25 ES22/E22 1-2 N/A Perform functional
Accelerometers ES23/E23 1-case check per
ES32/E32 2-case WP 4024 00
ES35/E35
* At room temperature or as specified in tables
Table 10-4 Chip Detector Resistance Values
Reference Component Resistance* Corrective
Component Figure Interface Pins (Ohms ±10%) Action
Chip Detectors 10-26 ES12/E12 1-2 Open Replace chip
ES13/E13 1-case Open detector per
2-case Open WP 1910 00
* At room temperature or as specified in tables
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Table 10-5 Temperature Sensor Resistance Values for TS-27
Reference Component Resistance* Comments
Sensor Component Figure Interface Pins (Ohms)
Group 1 Sensor 10-12 ES29/E29 A-B 1.0-4.0
Type K
Thermo- On-engine 10-12 ES29/E29 1-A Table 10-6 May be
couple harness 2-B Table 10-6 measured at
3-A Table 10-6 either end of
4-B Table 10-6 the on-
engine
harness (at
connector)
Off-engine 10-12 ES29/E29 1-A Table 10-6
cabling 2-B Table 10-6
3-A Table 10-6
4-B Table 10-6
Group 2 Sensor 10-21 ES34/E34, Al-Cr See Measure
Type K ES36/E36 WP 1711 00 both
Thermo- Terminal Case See terminals to
couple WP 1711 00 case
On-engine 10-21 ES34/E34, 1-2 Table 10-6 May be
harness ES36/E36 3-4 Table 10-6 measured at
5-6 Table 10-6 either end of
7-8 Table 10-6 the on-
engine
harness (at
connector)
Off-engine 10-21 ES34/E34, 1-1 Table 10-6
cabling ES36/E36 2-2 Table 10-6
3-3 Table 10-6
4-4 Table 10-6
5-5 Table 10-6
6-6 Table 10-6
7-7 Table 10-6
8-8 Table 10-6
Table 10-6
Group 3 Sensor 10-14 ES26/E26 A-B 4.3-6.0
Type K C-D 4.3-6.0
Thermo-
couple Off-engine 10-14 ES26/E26 A-A Table 10-6 May be
cabling B-B Table 10-6 measured at
C-C Table 10-6 either end of
D-D Table 10-6 the on-
engine
harness (at
connector)
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Table 10-5 Temperature Sensor Resistance Values for TS-27
Reference Component Resistance* Comments
Sensor Component Figure Interface Pins (Ohms)
Group 4 Sensor 10-15 ES9/E9 (Std) 1-2 Table 10-7 Standard and
RTD or ES14/E14 3-4 Table 10-7 optional
(Opt) sensors each
hour, two
200-ohm at
32°F (0°C)
RTDs in each
probe. Each
probe has an
integral lead
Off-engine 10-15 ES9/E9 (Std) Any Lead Continuity May be
cabling or measured at
ES14/E14 either end of
(Opt) the on-
engine
harness (at
connector)
Group 5 Sensor 10-15 ES1/E1 (Std) 1-2 Table 10-4 Standard and
RTD or 3-4 Table 10-4 optional
ES2/E2 (Opt) sensors each
hour, two
200-ohm at
32°F (0°C)
RTDs in each
probe. Each
probe has an
integral lead
Off-engine 10-15 ES1/E1 (Std) Any Lead Continuity May be
cabling or measured at
ES2/E2 (Opt) either end of
the on-
engine
harness (at
connector)
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Table 10-5 Temperature Sensor Resistance Values for TS-27
Reference Component Resistance* Comments
Sensor Component Figure Interface Pins (Ohms)
Group 6 Sensor 10-16 and ES19/E19 1-2 Table 10-8 Standard and
RTD 10-19 (Std) or ES17/ 3-4 Table 10-8 optional
E17 (Opt) sensors each
hour, two
200-ohm at
32°F (0°C)
RTDs in each
probe. Each
probe has an
integral lead
Off-engine 10-16 and ES19/E19 Any Lead Continuity May be
cabling 10-19 (Std) or ES17/ measured at
E17 (Opt) either end of
the on-
engine
harness (at
connector)
* At room temperature or as specified in tables
Table 10-6 Cable Circuit Resistance Values at Room Temperature (or as Specified in Table)
Cable Length Resistance (Ohms)
(ft) KP KN
10 1.3 - 2.1 0.5 - 0.9
20 2.6 - 4.3 1.1 - 1.8
30 4.0 - 6.4 1.7 - 2.7
40 5.3 - 8.6 2.2 - 3.6
50 6.7 - 10.7 2.8 - 4.4
60 8.0 - 12.9 3.4 - 5.3
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Table 10-7 T2 and T25 RTD Resistance Values for TS-27
Temperature Temperature Resistance
(°C) (°F) (Ohms ±10%)
-40 -40 163
-20 -4 184
0 32 200
20 68 215
40 104 232
60 140 250
NOTE All listed pins to ground > 100 kilo-ohm
Table 10-8 Lube RTD Resistance Values for TS-27
Temperature Temperature Resistance
(°C) (°F) (Ohms ±10%)
-40.0 -40.0 84
-17.8 0.0 92
0.0 32.0 100
10.0 50.0 104
37.8 100.00 115
65.6 150.00 126
93.3 200.00 137
121.00 250.00 150
148.9 300.00 159
176.7 350.00 170
204.4 400.00 181
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Table 10-9 Speed Sensor Resistance Values for TS-28
Reference Component Resistance
Component Figure Interface Pins (Ohms)
XN25 10-20 ES10/E10 1-2 200 ±10%
ES11/E11 1-2 200 ±10%
XNSD 10-22 ES30/E30 A-B Greater than
ES31/E31 A-B 500 ohms but less
than 2,000 ohms
XNSD 10-22 ES30/E30 A-CASE >500,000
ES31/E31 B-CASE >500,000
Table 10-10 Maximum Allowable Instrumentation and Accessory Temperatures
Component Temperature
Lube Oil RTDs 220°F (104°C)
XN2 Speed Sensors 140°F (60°C)
XN25 Speed Sensors 225°F (107°C)
XNSD Speed Sensors (Connector) 600°F (316°C)
Variable Stator Vane Actuators 350°F (177°C)
LPC Bleed Valve Actuators 300°F (149°C)
Accelerometer 500°F (260°C)
T48 Sensor (At Lugs) 600°F (316°C)
T3 Sensor (At Connector) 600°F (316°C)
VIGV Actuators 350°F (177°C)
VG Hydraulic Pump and Control Unit 220°F (104°C)
Lube Pump 300°F (149°C)
Starter 250°F (121°C)
Electrical Cable Panel No. 1 400°F (204°C)
Electrical Cable Panel No. 2 400°F (204°C)
Electrical Cable Panel No. 3 400°F (204°C)
Electrical Cable Panel No. 4 500°F (260°C)
Chip Detectors 350°F (177°C)
Balance Piston Air Valve 500°F (260°C)
UV Flame Detectors (GE Supplied) 302°F (150°C)
Thrust Balance Valve 250°F (121°C)
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Table 10-11 Orifice Dimensions
Part Number Diameter
L49438P01 0.73 in. (18.5 mm)
L49438P02 0.75 in. (19.1 mm)
L49438P03 0.77 in. (19.6 mm)
L49438P04 0.79 in. (20.1 mm)
L49438P05 0.81 in. (20.6 mm)
L49438P06 0.83 in. (21.1 mm)
L49438P07 0.85 in. (21.6 mm)
L49438P08 0.87 in. (22.1 mm)
L49438P09 0.89 in. (22.6 mm)
L49438P10 0.91 in. (23.1 mm)
L49438P11 0.93 in. (23.6 mm)
L49438P12 0.95 in. (24.1 mm)
L49438P13 0.97 in. (24.6 mm)
L49438P14 0.99 in. (25.1 mm)
L49438P15 1.01 in. (25.7 mm)
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4 CHAPTER 11
Maintenance Considerations
11-1 Purpose and Scope 11-3 Standard Maintenance
Practices
This chapter covers basic maintenance and
inspection practices and procedures to be fol- 11-3.1 Points of Reference
lowed during maintenance operations.
The following points of reference are used
11-2 Levels of Maintenance throughout this manual: forward, aft, right,
left, top, bottom, and clock position. These
The workscope for level 1 corrective mainte- points of reference are defined as follows:
nance allows replacement of external parts,
adjustments, and other work (preventive and Forward - the air intake end of the engine
corrective) up to and including removal and
replacement of the entire engine. Aft - the turbine end of the engine
The workscope for level 2 corrective mainte- Right - the right side of the engine when
nance permits the replacement of major viewed from the aft end and when the engine
engine sections (modules) and the replace- is in the normal operating position (gearbox
ment or repair of certain internal parts. Level 2 down)
maintenance is performed on-site on a nonin-
stalled engine or on an installed engine in the Left - the side opposite the right side
enclosure, as permitted by the enclosure
Top - the side of the engine that is up when the
design. Maintenance is performed with the
engine is in the normal operating position
engine horizontal. See Volume II.
Bottom - the side of the engine on which the
gearboxes are mounted
Clock Positions - the positions of the numbers
on a clock face as seen from aft, looking for-
ward. The 12:00 o'clock position is at the top,
3:00 o'clock is on the right side, 6:00 o'clock is
at the bottom, and 9:00 o'clock is on the left
side.
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11-3.2 Maintenance Within an NOTE Most of the tasks outlined can be done
Enclosure within the enclosure if the horizontal mainte-
nance option is selected, provided that tooling
WARNING When entering the gas turbine is available. Deviations from the procedures in
enclosure, the following requirements shall the Volume II work packages are permitted as
be met: necessary to adapt to the needs dictated by the
enclosure design, provided that these devia-
• The gas turbine shall be shut down.
tions do not compromise the intent of the
• Module entry during engine operation instruction. Some modular change-out may be
is prohibited in general. If entry should done within the enclosure and some outside,
be required during engine operation, whichever is more convenient. Consult the
contact GE Field Service for a represen- packager for planning assistance when ques-
tative who is trained to enter the module tions arise.
under such conditions. Observe all safety precautions listed below, as
well as those listed in Chapters 1 and 8.
WARNING The fire extinguishing system
must be deactivated before personnel enter a. Wear protective clothing, gloves, safety
the enclosure. Suffocation can occur if the glasses, etc. as required by the mainte-
fire extinguishing system is activated. nance to be performed.
WARNING The following steps must be b. Ensure the engine will not be started while
performed before entering the enclosure. personnel are inside the enclosure.
These conditions must be maintained while
inside the enclosure to prevent injury to c. Post an observer at the exit while mainte-
personnel. nance is being performed inside the enclo-
sure.
CAUTION All hardware items have been
manufactured to English measurement units. WARNING Electrical power to system on
Use of substitute metric sizes is not recom- which maintenance is being performed
mended and will void the warranty for inter- must be turned off to prevent arcing and
facing parts. Tools in metric sizes should be possible injury to personnel or damage to
furnished with suitable adapters to mate with components. Tag the switch “Out of Service
English measurement unit sizes given. Lim- for Maintenance” to prevent inadvertent
its, fits, and clearances may be interpreted in activation.
either English or metric units, as shown in
the tables. d. Turn off all electrical power, liquid, and air
service to system on which maintenance is
to be performed. Allow the engine to cool.
e. The following steps must be performed
upon exiting the enclosure after comple-
tion of maintenance:
(1) Ensure no personnel are inside the
enclosure.
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(2) Close the enclosure door. a. Torque values are expressed in lb in.
(pound-inches) or lb ft. (pound-feet). One
(3) Remove tag and turn on electrical pound-inch (or one pound-foot) is the
power, and liquid and air services. twisting force of one pound applied to a
twist-type fastener (such as a bolt or nut)
11-3.3 Electrical Bonding Straps with 1 inch (or one foot) of leverage. This
twisting force is applied to the fastener to
Electrical bonding strap contact surfaces shall secure the components.
be prepared by removing all anoxic film,
grease, paint, lacquer, or other high-resistance b. It is important to use the correct torque
material from an area at least one and one-half wrench for the amount of torque being
times the bonding surface contact area. Bonds applied. See table 11-1 for torque wrench
shall be installed and contact surfaces sealed ranges and requirements.
within 4 hours of cleaning. The area shall then
be painted to match the surrounding area. CAUTION If torque should increase signifi-
cantly prior to final seating of any threaded
11-3.4 Torque fastener, remove and inspect the fastener for
the cause of the torque increase.
In these maintenance procedures, it is assumed
that all threaded parts on the engine will be c. Never over-torque any fastener. Torque
tightened to a specific torque value. Special limits are provided in the text and in
torque values, if required, will be stated in the tables 11-2 through 11-5; these limits must
text; otherwise, standard torque values should be observed. Refer to paragraph 11-3.4.4
be used. for application information.
d. Do not use lubricant on bolt threads unless
specified in assembly procedures. Start
threads at least two turns by hand to ensure
proper engagement.
Table 11-1 Torque Wrench Ranges and Requirements
Torque Range Torque Wrench Capacity
0 - 25 lb in. (0 - 2.8 N·m) 0 - 30 lb in. (0 - 3.4 N·m)
25 - 140 lb in. (2.8 - 15.8 N·m) 0 - 150 lb in. (0 - 16.8 N·m)
140 - 550 lb in. (15.8 - 62.1 N·m) 0 - 600 lb in. (0 - 67.2 N·m)
30 - 140 lb ft (40.7 - 190 N·m) 0 - 150 lb ft (0 - 203 N·m)
140 - 240 lb ft (190 - 325 N·m) 0 - 250 lb ft (0 - 339 N·m)
240 - 1000 lb ft (325 - 1356 N·m) 0 - 1000 lb ft (0 - 1356 N·m)
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Table 11-2 Torque Values for Steel Bolts, Nuts, and Self-Locking Nuts
Torque Value
Size Threads Per Inch lb in. N·m
8 32 13-16 1.5-1.8
10 24 20-23 2.3-2.5
1/4 20 40-60 4.5-6.8
5/16 18 70-110 7.9-12.4
3/8 16 160-210 18.1-23.7
7/16 14 250-320 28.2-36.2
1/2 13 420-510 47.5-57.6
8 36 16-19 1.8-2.1
10 32 33-37 3.7-4.2
1/4 28 55-70 6.2-7.9
5/16 24 100-130 11.3-14.7
3/8 24 190-230 21.5-26.0
7/16 20 300-360 33.9-40.6
1/2 20 480-570 54.2-64.4
Table 11-3 Torque Values for Engine Plugs and Unions
Tube OD Fitting
(inches) Dash No. Torque Value
1/8 2 40-50 lb in. (4.5-5.6 N·m)
3/16 3 90-100 lb in. (10.2-11.3 N·m)
1/4 4 135-150 lb in. (15.3-16.9 N·m)
5/16 5 155-175 lb in. (17.5-19.8 N·m)
3/8 6 180-200 lb in. (20.3-22.6 N·m)
1/2 8 270-300 lb in. (30.5-33.9 N·m)
5/8 10 360-400 lb in. (40.7-45.2 N·m)
3/4 12 45-50 lb ft (61.0-67.8 N·m)
1 16 58-70 lb ft (78.6-94.9 N·m)
1-1/4 20 75-87 lb ft (102-118 N·m)
1-1/2 24 83-100 lb ft (113-136 N·m)
11-1
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Table 11-4 Torque Values for Tubing Nuts and Hose Fittings
Hose Aluminum Female Steel Female Sealing
Tube OD Dash No. Sealing Surfaces Surfaces
(Inches) (Size) (See Note 1) (See Note 2)
lb in. N·m lb in. N·m
0.125 (1/8) 2 - - 40-50 (4.5-5.6)
0.1875 (3/16) 3 30-50 (3.4-5.6) 90-100 (10.2-11.3)
0.250 (1/4) 4 40-65 (4.5-7.3) 135-150 (15.3-16.9)
0.3125 (5/16) 5 60-80 (6.8-9.0) 180-200 (20.3-22.6)
0.375 (3/8) 6 75-125 (8.5-14.1) 270-300 (30.5-33.9)
0.500 (1/2) 8 150-250 (16.9-28.2) 450-550 (50.8-62.1)
0.625 (5/8) 10 200-350 (22.6-39.5) 650-770 (73.4-87.0)
lb ft N·m lb ft N·m
0.750 (3/4) 12 25-41 (33.9-55.6) 75-91 (102-123)
1.000 (1) 16 41-58 (55.6-78.6) 112-128 (152-174)
1.250 (1-1/4) 20 50-75 (67.8-101) 133-150 (180-203)
1.500 (1-1/2) 24 50-75 (67.8-101) 158-183 (214-248)
Notes: 1. These values apply when female sealing surface is aluminum. Male connector and nut
may be either steel or aluminum.
2. These values apply when female sealing surface is steel. Male connector and nut may
be either aluminum or steel.
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Table 11-5 Torque Values for Plugs and Unions Used in Bosses and for Universal Bulkhead Fitting Locknuts
Dash No. Threads Torque
(Size) Size Per Inch lb in. lb ft N·m
2 0.3125 24 40-50 5.2-5.6
3 0.375 24 90-100 10.2-11.3
4 0.4375 20 135-150 15.3-16.9
5 0.500 20 155-175 17.5-19.8
6 0.5625 18 180-200 20.3-22.6
8 0.750 16 270-300 30.5-33.9
10 0.875 14 360-400 40.7-45.2
12 1.0625 12 540-600 45-50 61.0-67.8
16 1.3125 12 700-850 58-70 78.6-94.9
20 1.635 12 900-1050 75-87 102-118
24 1.875 12 1000-1200 83-100 113-136
Figure 11-1 Tightening Sequence for Threaded Fasteners
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11-3.4.1 Tightening Procedures e. Washers are installed beneath the part that
turns when tightening, unless otherwise
CAUTION When chilling or heating an specified.
engine part during assembly, do not torque
spanner nuts, locknuts, or retaining bolts f. The torque wrenches listed in table 11-1
until the part has returned to room tempera- are recommended for use within the indi-
ture. The fastener may loosen as the part cated ranges. Larger wrenches have too
cools or may be overstressed as the part great a tolerance and can result in inaccu-
warms and expands. racies.
a. If possible, tighten at a uniformly increas- g. Torque values specified in this manual are
ing rate until the desired torque is actual values to be applied to fasteners.
obtained. In cases where gaskets or other Whenever an adapter (crowfoot, spanner
parts cause a slow permanent set, be sure wrench, etc.) is used with a torque wrench,
to hold the torque at the desired value until torque must be calculated per figure 11-2.
the material is seated.
h. Inspect all nuts and bolts after tightening
b. Apply uniform torque to a series of bolts to make sure they are seated. If any nut or
that have different diameters and are bolt is not seated after the required torque
installed on one flange or in one area. has been applied, remove and inspect for
Torque shall be less than the final torque thread damage.
required for the smallest diameter bolt.
This prevents shearing or breaking of tight i. Lubricate tube/hose connector threads and
bolts due to force concentrations. between the B-nut and ferrule of a connec-
tor. Run B-nuts onto fittings by hand to
c. It is not desirable to tighten to the final ensure that tubes and hoses are aligned and
torque value during the first drawdown; threads are free of burrs. Two wrenches
uneven tension can cause distortion or must be used when loosening or tightening
overstressing of parts. Torque mating parts B-nuts, one on the fitting to which the tube
by tightening the bolts or nuts gradually or hose is being connected to hold it sta-
until the parts are firmly seated. Loosen tionary and one on the B-nut for torquing.
each fastener by one-quarter turn, then This not only prevents twisting the tube,
apply final tightening. Tightening in a dia- but also prevents loosening or overtighten-
metrically opposite (staggered) sequence ing the fitting. When using an extension on
is desirable in most cases (figure 11-1). Do a torque wrench, calculate the correct
not exceed listed maximum torque values. torque input before applying torque per
figure 11-2.
d. All bolts are installed with heads forward
11-2
and up with nuts aft and down, unless oth-
erwise specified.
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Figure 11-2 Torque Wrench Correction Factor Determination
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11-3.4.2 Running Torque 11-3.4.3 Loose Fasteners
Refer to table 11-6 for minimum breakaway Prior to retightening, examine the fastener for
torque on self-locking nuts. This table applies the cause of the looseness. If safety wire is
to silver-plated, lubricated, and nonlubricated missing, tighten to the required torque and
self-locking nuts. Values given are for nuts safety-wire the fastener. If the fastener has a
with no axial load. To check minimum break- self-locking feature, check breakaway torque
away torque, screw the nut onto a bolt until per the preceding step. Replace defective fas-
two to five threads are exposed beyond the teners as required.
nut. Measure the amount of torque required to
11-3.4.4 Standard Torque
turn the nut on or off the bolt. Nuts that do not
meet these minimum frictional requirements Use the following standard torque tables,
should be replaced. unless otherwise directed in the text.
Table 11-6 Minimum Running Torque for Self-
a. Use the torque values given in table 11-2
Locking Nuts
for steel bolts and nuts (including self-
Minimum Breakaway Torque locking nuts). Values given are for clean
bolts and nuts that are free of nicks and
Threads/
Size Inch lb in. N·m burrs.
0.136 (6) 32/40 1.0 0.1 b. Use half the value given in table 11-2 for
the following applications:
0.164 (8) 32/36 1.5 0.2
0.190 (10) 32 2.0 0.2 (1) Thin steel hex nuts - These nuts have
a height of less than 0.60 inch (15.2
1/4 28 3.5 0.4
mm) of the inside diameter for plain
5/16 24 6.5 0.7 nuts and less than 0.80 inch (20.3
mm) of the inside diameter for self-
3/8 24 9.5 1.1
locking nuts.
7/16 24 14.0 1.6
(2) Nonsteel nuts and bolts except
1/2 20 18.0 2.0
titanium.
9/16 18 32.0 3.6
(3) All bolts threaded directly into alumi-
5/8 18 50.0 5.6 num, magnesium, or other non-steel
3/4 16 50.0 5.6 parts.
c. Use the torque values given in tables 11-3
and 11-4 for gasketed fittings. Install fit-
tings as illustrated in figure 11-3. Torque
values given in tables 11-3 and 11-4 are
for packing made of synthetic material,
asbestos compounds, or soft metal (cop-
per, aluminum, etc.). These values do not
apply to steel gaskets or special boss seals.
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11-3
Figure 11-3 Universal Fittings Installation
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11-4
Figure 11-4 Tri-Wing Fastener Drive
11-3.5 Tri-Wing Fasteners wing recess identification numbers.
Tri-wing recessed-head fasteners are available b. Ensure the axis of the drive is aligned with
in a wide range of sizes, and each size requires the axis of the fastener when installing or
the use of a matched driver. See figure 11-4. removing the fastener. If the head of the
When properly used, the tri-wing design per- fastener has been coated with paint or
mits a higher ratio of torque to end-pressure other material, use a driver one size
than is possible with slotted-head or cross- smaller than that indicated, to compensate
head designs, minimizing burring and mutila- for the thickness of material on the walls
tion. The following procedures should be used of the recess.
for tri-wing fasteners.
11-3.5.2 Extraction
11-3.5.1 Installation
a. There is no slope to the walls of mating
surfaces of either fastener or driver, so that
a. Select the correct driver. The driver num-
the tendency of the driver to slip out of the
ber should match the recess number of the recess is minimized. Normal extraction by
fastener head as shown in figure 11-4. applying counterclockwise torque is usu-
Table 11-7 lists a range of standard fas- ally successful.
tener sizes with their corresponding tri-
Change 6 11-11
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Table 11-7 Tri-Wing Drivers and Standard-Thread 11-3.6 Marking of Parts
Fasteners
a. Parts or assemblies designated as matched
Tension Shear
Screw Thread Size sets must be maintained as matched sets
Head Head
throughout maintenance activity. Set num-
0 - 80 0 -
bers, part numbers, and serial numbers
2 - 56 1 - shall be protected during cleaning or
4 - 40 2 1 rework to prevent removal. When identifi-
6 - 32 3 2
cation markings are removed or are no
longer legible, the item must be re-marked
8 - 32 4 3 per the original marking method and at the
10 - 32 5 4 location specified on the applicable draw-
1/4 - 28 6 5 ing. Do not use electrochemical etch
5/16 - 24 7 6
method to re-mark part.
3/8 - 24 8 7 CAUTION Whenever it is necessary to mark
7/16 - 20 9 8 any engine parts, only approved marking
1/2 - 20 10 9 compounds shall be used. Use of unautho-
rized marking compounds can cause damage
9/16 - 18 11 10
to engine parts.
5/8 - 18 12 11
3/4 - 16 13 12 b. Permanent marking of parts should be
done in the area of lowest stress, as speci-
7/8 - 14 14 13
fied on the applicable drawing. Methods
1 - 12 15 14 are listed below in order of preference
(unless otherwise specified). Electric etch
b. If corrosion or other factors have caused is not approved.
the fastener to seize so that failure of the
recess occurs, select the proper drill and c. Marking methods are:
screw extractor for the size of fastener
involved. The bottom of the fastener (1) Dot peen - preferred - optical charac-
recess is shaped so that the drill centers ter recognition (OCR) is DM3. The
itself naturally and no special drilling pro-
OCR requirement defines the charac-
cedure is required. Drill into the fastener
deep enough to provide sufficient working ter height, width, and spacing.
depth for the screw extractor. Tap the
extractor to seat it firmly, then apply coun- (2) Vibropeen - acceptable
terclockwise torque to remove the fastener.
(3) Metal stamp - special use only
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CAUTION Grease or lead (graphite) pencils NOTE
must not be used to mark combustion-section
or hot-section parts. These materials plus • Although not every possible combination
heat can cause parts material damage. of safety-wiring is shown in figure 11-5, all
safety-wiring must, in general, corre-
d. Lead- and sulfur-containing materials spond to the examples shown.
should not be used for marking any parts.
Preferred materials are listed below: • GE gas turbines use special locking cables
at some locations. When removed for
• Sharpie T.E.C. maintenance, these should be replaced
with equivalent cables or safety wire using
• Chalk standard safety-wiring procedures in this
chapter.
• Dykem - red, yellow, black
11-5
11-3.7.1 Safety-Wiring General
• Ink - Justrite Slink Black; Marco Practices
S-1141, black
The following rules for safety-wiring shall be
• March Stencil Ink observed, unless specific instructions to the
contrary are given in the text.
• Carters Marks-A-Lot - black
• Safety wire shall consist of two strands of
• Carters Marks-A-Lot - blue
wire twisted together (so called double-
• Dixon - black twist method), where one twist is defined
as being produced by twisting the strands
• Dixon - yellow through an arc of 180°, equivalent to half a
complete turn. Use the single-strand
• Dykem Steel Blue DX100 method only when specified.
• Soapstone • Safety wire shall not be installed in a man-
ner to cause the wire to be subjected to
11-3.7 Safety-Wiring chafing, fatigue through vibration, or addi-
tional tension other than the tension
Safety-wiring is the securing of two or more imposed on the wire to prevent loosening.
parts with a wire installed in such a manner
that any tendency for a part to loosen will be • In all cases, safety-wiring must be done
counteracted by additional tightening of the through the holes provided. If no wire hole
wire. This is not a means for obtaining or is provided, safety-wiring shall be to a
maintaining torque, but rather a safety device neighboring part in a manner not to inter-
used to prevent the disengagement of parts. fere with the function of the parts and in
See figure 11-5 for general safety-wiring prac- accordance with the basic principles
tices. described.
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Figure 11-5 Safety-Wiring Practices (Sheet 1 of 2)
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Figure 11-5 Safety-Wiring Practices (Sheet 2 of 2)
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• The maximum span of safety wire • When removing safety wire, identify
between tension points shall be 6 inches safety-wiring holes on parts.
(152 mm), unless otherwise specified.
Where multiple groups are safety-wired 11-3.7.2 Safety Wire Installation
either by the double-twist or the single-
strand method, the maximum number in a The following safety-wiring procedures are to
series shall be determined by the number be used throughout the engine:
of units that can be safety-wired with a 24-
a. Insert the safety wire through the first part
inch (610 mm) length of wire. When
and bend the upper end either over the
safety-wiring widely spaced multiple
head of the part or around it. If bent around
groups with the double-twist method, the
it, the direction of wrap and twist of the
maximum number in a series shall be three
strands shall be such that the loop around
units.
the part comes under the strand protruding
• Both 0.020-inch (0.51 mm) and 0.032-inch from the hole. Done this way, the loop will
(0.81 mm) safety wires are used through- not tend to slip upward and become slack.
out the engine. The application is deter-
b. Twist the strands while taut until the
mined by the size of the hole in the unit to
twisted portion is just short of the nearest
be safety-wired. Whenever possible, use
hole in the next part. The twisted portion
the 0.032 inch (0.813 mm) safety wire.
should be within 1/8 inch (3.2 mm) of the
Only new safety wire shall be used in each
hole in each part.
application.
c. If the free strand is to be bent around the
• The safety wire shall be pulled taut while
head of the second part, insert the upper
being twisted, and shall have 9 to 12 twists
strand through the hole in this part, then
per inch (25 mm) for 0.020 inch (0.51
repeat the previous step. If the free strand
mm) diameter wire and 7 to 10 twists per
is to be bent over the unit, the direction of
inch for 0.032 inch (0.81 mm) diameter
twist is unimportant. If there are more than
wire.
two units in the series, repeat the preced-
• Hose and electrical coupling nuts shall be ing steps.
safety-wired in the same manner as tube
d. After wiring the last part, continue twist-
coupling nuts.
ing the wire to form a pigtail of three to
• Caution must be exercised while twisting eight twists (1/4-1/2 inch [6-13 mm] long)
to keep the wire tight without overstress- and cut off the excess wire. Bend the pig-
ing it or allowing it to become nicked, tail inward toward the part in such a man-
kinked, or otherwise mutilated. ner as to prevent it from becoming a
hazard to personnel.
• Only existing safety wire should be
replaced; do not add safety wire which
was not previously in place or specified in
text.
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NOTE Apply light finger pressure at the mid- h. When removing safety wire, ensure that all
point of the safety wire span, and flex the wire pieces are removed to prevent them from
in both directions to check for tautness. entering engine parts or otherwise causing
damage.
e. If the safety wire is not taut after safety-
wiring per the preceding instructions, use 11-3.8 Safety Cable
the limits shown in table 11-8 to determine
its acceptability. Safety cable is an alternative to safety wire.
Safety cable is installed through two or more
f. If the safety wire fails to meet the limits parts in such a way that as the fastener or part
shown in table 11-8, remove it and install loosens the safety cable will tighten. When the
new safety wire. safety cable tightens, it will not permit the fas-
tener to part or turn.
Table 11-8 Installed Safety Wire Flex Limit
Length of Safety Wire Total Flexing at 11-3.8.1 Safety Cable General
Between Parts Center Practices
in. mm in. mm The safety cable system has three compo-
1/2 13 1/8 3 nents: safety cable, ferrules, and crimping
tool.
1 25 1/4 6
2 51 3/8 10 • The safety cable is available in one size,
0.032 inch (0.81 mm). One end of the
3 76 1/2 13
cable will have a cable end fitting swaged
4 102 3/4 19 to it. The strands of the cable on the oppo-
site end of the cable are fused together to
5 127 3/4 19
prevent the cable from fraying.
6 152 3/4 19
• The ferrules have spring-loaded, dispos-
g. Always cut, rather than break, safety wire able magazine. When the safety cable is
so that safety wire holes are not torn or installed, the ferrule will be crimped on the
pulled out. Instructions for dismantling open end of the cable.
and disassembly do not include safety wire • The hand operated crimping tool operates
removal because of the obvious necessity in one direction only and has a cycle end
for removing safety wire. dead stop to tell the operator when the fer-
rule is fully crimped. The crimping pres-
WARNING Use extreme caution in moni-
sure of the tool is set by the manufacturer.
toring the safe and complete removal of all
If necessary, the crimping pressure can be
excess safety wire. Care must be taken
adjusted with standard hand tools. The
when cutting off the ends of installed wire
Snap-On tool has a spring-loaded crimp
to ensure complete retrieval in order to pre-
rod to hold the ferrule in place during the
vent injury to personnel and/or subsequent
crimping procedure. Cable tension is done
engine damage.
automatically by the internal retraction
mechanism.
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• Where possible, install the safety cable so NOTE Keep the safety cable as straight as
it does not touch other parts. possible when you safety cable the fasteners
or parts together.
• Make sure the cable is not damaged or
bent when installing safety cable through b. Put the end of the cable without the cable
the holes in the fastener or part. Frayed end fitting into the hole in the part. Pull the
cable assemblies are not permitted. cable through the hole until the cable end
fitting is against the part.
• Install the safety cable through existing
holes only. c. Insert the end of the cable through the sec-
ond part. Choose the hole in the part that
• Unless specified differently in the pack- permits the cable to be as straight as possi-
ager's manual: ble. Pull the cable through the second part.
If three parts must be safety cabled, do the
The maximum length of the safety cable same procedure for the third part.
between safety cabled parts is 6.0 inches
(152.4 mm). NOTE On a two bolt pattern, do not cable in
a negative pull direction. Make sure the cable
No more than three bolts can be safely tied has a positive or neutral pull.
with one safety cable.
d. Put the end of the safety cable coming out
Safety cable can not be used on titanium of the last part to be safety cabled through
fasteners. a ferrule in the ferrule magazine. Pull the
safety cable through the ferrule and use the
11-3.8.2 Crimping Tool Verification safety cable to pull the ferrule out of the
ferrule magazine.
Do a pulloff load test as necessary to make
sure the crimp done by the crimping tool e. Put the end of the safety cable through the
meets the necessary requirements. GE Aircraft crimping head of the crimping tool. Make
Engines recommends the pulloff load test be sure the large hole in the crimping head is
done at the beginning, middle, and end of each on the same side as the ferrule. Move the
shift. Refer to manufacturer's instructions for crimping tool along the safety cable until
pulloff load test procedure. the crimping head is against the ferrule.
Pull back on the retraction knob. Put the
11-3.8.3 Safety Cable Installation
ferrule in the crimping head and release
a. Do a visual inspection of the holes to be the retraction knob. Make sure the ferrule
safety cabled to find all damage. If the is fully in the crimping head.
hole is damaged, replace the part, or if
possible, use another hole to safety cable.
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CAUTION Do not put too much tension on m. Push against the safety cable with light
the safety cable. The crimping tool will auto- finger pressure halfway between the safety
matically set the tension. Too much tension cabled parts. If the cable feels loose, do a
will break the safety cable. dimensional check to make sure the safety
cable is serviceable as follows (see
f. Pull the safety cable to the tension post on figure 11-6):
the crimping tool. Wrap the cable com-
pletely around the post. Make sure the (1) Measure the distance between the
cable is in the groove at the top of the post. safety cabled parts. Write this mea-
Pull the cable toward the drive handle until surement down as Dimension A. If
the cable goes behind the locking ball. three parts are safety cabled together,
measure the distance between each of
g. Hold the crimping tool perpendicular to the parts and add the two measure-
the cable in the bolt head. Make sure the ments together to get Dimension A.
ferrule is tightly against the bolt head.
Lightly pull on the end of the safety cable (2) Push against the safety cable with
to remove slack. light finger pressure halfway between
two safety cabled parts. Measure the
h. Push the start cycle button and turn the distance the safety cable moves later-
drive handle clockwise. At the start of the ally. Write this measurement down as
cycle, the tension block will move back- Dimension C.
wards. This movement backwards pro-
vides the cable tension. When the drive (3) Compare the dimensions that were
handle is turned, release the start cycle written down to the limits given in
button. Turn the drive handle until it stops figure 11-6.
(approximately two full turns).
CAUTION Do not try to break the safety
i. Pull up on the safety cable end to remove cable. If the safety cable must be removed,
it from the tension block. cut the safety cable to avoid damage to the
holes in the parts.
j. Pull back on the retraction knob and
remove the crimping tool from the n. If the safety cable is not in the limits given
crimped ferrule and the remaining safety in figure 11-6, cut the safety cable with
cable. wire cutters and remove the installed
safety cable. Install new safety cable.
k. Cut the unused safety cable even with the
11-6
crimped ferrule. Use the side cushioned 11-3.9 Correction of Leaks
cutters. Discard the unused safety cable.
CAUTION Do not over-torque threaded fas-
l. Visually inspect safety cable for kinks, teners as a method of correcting leaking con-
frayed wires, or improper crimps. Remove nections. Over-torquing could result in part
and replace safety cable if a problem failure.
exists.
a. Disassemble the connection.
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Figure 11-6 Safety Cable Flex Limits
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b. Discard the seal, gasket, or packing, if Make sure all ports, openings, connec-
present. tions, and mating surfaces are capped or
covered, and that the part is protected from
c. Inspect mating surfaces for contamination, potential handling or environmental dam-
scratches, dents, or other surface defects. age.
d. Inspect threaded fasteners for thread dam- f. Bearings shall be handled per paragraph
age and ensure that fasteners seat properly 11-3.20 in this chapter.
when torqued to specified values.
11-3.11 Jackscrews
e. Replace nonserviceable parts and assem-
ble the connection, using new seals, gas- a. When using jackscrews to remove compo-
kets, or packing as required. nents, do not bend flanges or strip threads.
Lubricate jackscrews with engine lube oil
11-3.10 Unpacking and Repacking before installing. Turn jackscrews inward
evenly and in small increments. Always
The following general instructions apply dur- check for and remove burrs or rough edges
ing unpacking and repacking to minimize pos- before using jackscrews. If regular bolts
sible part damage and contamination. are used as jackscrews, the tips must be
blunt and polished. Do not allow compo-
a. Initially, remove only that portion of the nents to fall free as jackscrews are tight-
packing material necessary to mount the ened.
part. Where possible, remove the remain-
der of the packing material, including b. Jackscrew holes are often in flanges that
protective caps and plugs, one at a time as are only thick enough for three or four
each connection (fluid, air, or electrical) is threads. The ends of most standard bolts
made. are chamfered, and the first couple of
threads are missing or incomplete. These
b. Retain protective caps and plugs and reus- should not be used as jackscrews without
able packing components for repacking modification, since only one or two
purposes. threads will engage and the threads in the
flange are likely to strip.
c. Install a cap or plug on each connection
(fluid, air, or electrical) as it is discon- c. Jackscrews, frequently designed as special
nected. tools and identified as such, are not cham-
fered and full thread engagement will
d. When possible, repack the part for storage
occur. If specially manufactured jack-
or shipment, using the same packing mate-
screws are not available and must be man-
rial in which the replacement part was
ufactured locally, be sure that the ends are
received.
ground to remove the chamfer and the
e. When original packing components are incomplete thread so that the maximum
not available, use locally available packing number of threads may be engaged.
materials and containers to pack the part.
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11-3.12 Protective Closures and Caps f. Reinstall the fitting and screw it down to
its final position.
a. Preventing foreign material from lodging
in drilled passages, fuel lines, oil lines, air Union
lines, and open engine ports is extremely
important. Machined surfaces must be a. Lubricate the packing and roll it over the
properly protected to prevent damage. threads into the groove in the union.
b. Wrap precision parts and cap or plug all b. Screw the union into the boss until the
openings and connections. It is most packing contacts the surface of the boss.
important that all engine parts be kept
clean and free of corrosion. All instruc- c. Tighten the union to the proper torque
tions that specify special handling of parts value.
must be followed without exception.
Bulkhead fitting
c. Accessories, tubes, and hoses may contain
a. Lubricate the fitting end. Screw the nut
fuel or oil at the time of removal. Drain
onto the fitting until the washer face of the
these fluids from the accessory being
nut is aligned with the upper corner of the
removed and cap all connecting hoses or
seal groove.
tubes. Do not use tape.
b. Lubricate the packing and roll it over the
d. Do not remove plugs, caps, etc., until the
threads into the groove in the fitting so that
part is ready for assembly. Check both
it contacts the nut.
seating surfaces for removal of plugs, etc.
prior to assembly. c. Screw the fitting and nut simultaneously
into the boss until the seal contacts the
11-3.13 Universal Fittings
chamfer at the face of the boss and the nut
Universal fittings should be installed accord- contacts the boss.
ing to the procedures described below (figure
d. Position the fitting either by turning in as
11-3).
much as three-quarters of a turn (270°
Pipe fitting clockwise) or turning out as much as one-
quarter turn (90° counterclockwise).
a. Inspect the fitting visually. Attach the line to the fitting and check the
alignment of the fitting. Tighten the nut to
b. Clean if necessary. the proper torque.
c. Lubricate mating fittings. Fittings with backup rings
d. Install the fitting, screwing it down to a. Lubricate the male threads of the fitting,
within one-half turn of final position. the backup ring, and the packing.
e. Remove the fitting, clean, inspect, and b. Screw the nut onto the fitting, with the
lubricate the male thread. counterbore side facing the fitting end.
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c. Put the backup ring on the fitting and seat d. Mating flanges, tube flanges, and cou-
it in the counterbore of the nut, with its plings shall be wiped clean to make sure
convex side facing the fitting end. that a good seal will be obtained.
d. Roll the packing over the threads into the e. Hands and gloves must be clean when
groove in the fitting. handling machined surfaces.
e. Adjust the nut so the backup ring forces f. The engine shall not be used as a shelf for
the packing firmly against the lower holding tools or parts while maintenance is
threaded portion of the fitting. being performed.
f. Screw the fitting and nut simultaneously g. After performing any maintenance, the
into the boss until the packing contacts the work area shall be thoroughly inspected
chamfer at the face of the boss. for loose parts, rags, tools, and other mate-
rials. The area shall be cleaned to remove
g. Hold the nut and turn the fitting one-and- grit, dust, chips, safety wire, and other
a-half turns into the boss. The fitting may small objects.
be positioned further by one additional
turn. 11-3.15 Gaskets and Packing
h. Attach the line to the fitting and check the a. Gaskets, packing, key washers, and cotter
alignment of the fitting. pins shall not be reused, unless otherwise
specified.
i. Hold the fitting and tighten the nut to the
proper torque. b. Gaskets and packing shall be lightly lubri-
cated with engine lube oil prior to installa-
11-3.14 Cleanliness tion, unless otherwise specified. Ensure
parts are properly seated. When a fitting
Cleanliness is important for equipment life with a jamnut and packing is used, see fig-
and proper operation. The major cause of pre- ure 11-3 for the proper installation proce-
mature engine removal is foreign object dam- dure. See figure 11-7 for packing used
age (FOD). with flexible sleeve type fittings.
a. The enclosure must be kept clean and free 11-7
11-3.16 Tubes
of dirt and loose objects. It is recom-
mended that small FOD containers be kept When installing tubes, the following precau-
in the work area or in tool boxes. tions and instructions apply. See figure 11-7.
b. All parts shall be inspected for cleanliness a. As tubes are installed, tighten all
before being installed. end-fittings and clamps finger-tight. After
a complete system is installed, torque
c. Gaskets and packing shall be free from
end-fittings first and then clamps.
dirt, lint, and/or grit.
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Figure 11-7 Flexible Coupling Assembly
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• Maintain a minimum clearance of tion, be sure that no hose is twisted or
0.125 inch (3.2 mm) between tubes stretched. Never over-torque connectors.
and adjacent parts. When hoses are removed, cap the open
ends. Do not use tape to cover open ends.
• Tubes and manifolds must fit within
0.063 inch (1.6 mm) radius in a free Table 11-9 Hose Minimum-Bend Radii
state during assembly or be replaced. Dash Minimum-Bend Radius
• Coupling nuts shall thread freely by Size in. mm
hand. 3 1.50 38
• Mating flanges on tubes shall seal 4 2.00 51
flush within 0.005 inch (0.13 mm). 5 2.00 51
• The distance between faces of mating 6 4.00 102
surfaces or flanges shall not exceed 8 4.62 117
0.063 inch (1.6 mm).
10 5.50 140
• If tubes are reworked, the bend radii 12 6.50 165
shall not be less than twice the tube
diameter and the bend angle shall not 16 7.38 187
be changed by more than 3 degrees. 20 11.00 279
No kinks or wrinkles are permitted.
24 14.00 356
• Do not bend tubes at fitting or weld 32 22.00 559
areas.
CAUTION Natural gas fuel hoses and fuel
• Original bends in a tube may be bent in
nozzle steam hoses have different and more
the same direction, but reverse bending restrictive requirements. Refer to the appro-
is not allowed. priate work package in Volume II for details.
• Bend tubes in existing straight sec- b. Fluid fittings shall be tightened gradually
tions, if possible. to the required torque value, backed off
one-quarter turn, and then tightened again.
Use bending tools on any tube 1 inch or more
Do not attempt to correct leaks by exces-
in diameter to prevent the tube from collaps-
sive tightening. Always use two wrenches
ing.
when tightening swivel coupling nuts on
11-3.17 Hoses hoses, tubes, or fittings. Hold the station-
ary part with one wrench while applying
a. No hose should be bent more than the torque with second wrench. Apply engine
bend radius specified in table 11-9, espe- lube oil between the tube/hose coupling
cially when parts are cold, because of pos- nut and the ferrule prior to tightening. See
sible damage to Teflon liners. Kinked figure 11-8.
hoses must not be used. During installa-
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Volume I GE Industrial AeroDerivative Gas Turbines
c. Preformed hoses or hoses of large diame- a. Remove the unserviceable seal.
ter shall not be bent or straightened. See
figure 11-9. When hoses are removed, cap b. Engage the new seal over the barrel of the
the open ends. Do not use tape to cover connector.
open ends.
CAUTION Do not allow the seal to tip and
d. Before installing preformed hoses, visu- flatten. An incorrectly installed seal could
ally inspect the hose interior to assure that affect the usefulness of the seal and/or con-
the Teflon lining has not been damaged. If nector.
damaged, replace the hose.
c. Push the seal to its seated position against
11-8
11-9 the internal shoulder in the connector
11-3.18 Clamps using a mating connector or blunt screw-
driver.
a. Chafing of hoses and tubes must be
avoided. Clamp parts loosely in place, CAUTION Do not force the connectors
shift the hoses until the best clearance is together. If the pins are not aligned, they will
obtained, and then tighten the clamps be bent or distorted and will not make con-
(figure 11-10). tact.
b. Clamps must be of the proper size for the d. Inspect electrical connector pins for
piping to permit slippage during engine straightness before connecting. Insert the
thermal growth. The cushion clamp liner mating cable connector, hand-tighten the
position should also be checked before retaining nut, push the mating parts
tightening the clamp (figure 11-11). together until seated, and tighten the
Clamps must be positioned over the wear retaining nut as required.
sleeves on the tube.
11-10
11-11 e. If the connector is a locking connector,
11-3.19 Electrical Cables and engage the connector and wiggle the back-
Connectors shell while tightening the coupling ring
hand-tight. A clicking sound is produced
During electrical cable installation, adjust the during tightening of the connector. Ensure
cable through the clamps to get the smoothest that the full coupling color band on the
and largest radius. Sharp bends, twists, and receptacle is not visible and that the back-
kinks must be avoided. Minimum clearance shell has no movement.
between the electrical cable and any compo-
nent other than hoses or other electrical cables f. Electrical connectors on flexible harnesses
is 0.125 inch (3.18 mm). and leads shall be hand-tightened beyond
finger-tight (20° maximum) until connect-
A seal ring is located in the coupling nut of ing parts are in solid contact without dam-
each electrical connector. Inspect to ensure the age. Safety-wire the connectors only when
seal is present and serviceable before attach- specified in the procedure.
ing the connector. Replace unserviceable seals
as follows:
11-26 Change 6
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Figure 11-8 Hose Assemblies Installation
Change 6 11-27
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
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Figure 11-9 Factory Preformed Hoses
Figure 11-10 Routing and Clamping Techniques
11-28 Change 6
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Figure 11-11 Cushion Clamps Installation
g. Do not sharply bend, kink, or twist rigid 11-3.20.1 Preservation
leads. When tightening the connection,
always hold both mating connectors to WARNING Lubricating oil, MIL-L-6085,
prevent damage to the leads. is flammable and toxic to skin, eyes, and
respiratory tract. Skin, eye, and respiratory
11-3.20 Bearing Handling protection is required.
CAUTION Ball and roller bearings require At the point where bearings are accessible in
special care to prevent corrosion. Bearings the disassembly cycle, the bearings shall be
must not be handled with bare hands nor thoroughly covered with lubricating oil,
with any device that might cause contamina- MIL-C-6085.
tion. Clean rubber or nylon gloves or a pro-
tective hand cream shall be used at all times Use of engine lubricating oil as a lubricant or
when handling bearings. preservative is specifically prohibited.
Personnel handling bearings must wear either
synthetic rubber or nylon-mesh gloves with
polyethylene palms and fingers.
Change 6 11-29
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
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WARNING Corrosion preventive, MIL-C- CAUTION
11796, is flammable and toxic to skin, eyes,
and respiratory tract. Skin, eye, and respi- • Immediately after installing or removing
ratory protection is required. a chilled bearing, use a heat gun to
restore the bearing and any adjacent cold
Bearings returned to storage shall be pre- area to room temperature so that conden-
served with corrosion preventive, MIL-C- sation of moisture will be minimized.
11796, Class 3, and wrapped in barrier paper, Check carefully for evidence of moisture
MIL-B-121, Grade A, Type 2, Class 2, glossy and continue heating until the bearing is
side toward bearing. completely dry. Apply corrosion preven-
tive, MIL-C-6529, Type III, at once to the
After installation, bearings shall be returned to bearing after complete drying.
room temperature and be preserved with lubri-
cating oil, MIL-C-6085. • When heat is required to relieve shrink
fits of bearings, use heat guns or ovens.
11-3.20.2 Heating and Chilling Do not use direct-heat sources to apply
the heat and do not heat the bearings to a
WARNING temperature higher than 350°F (175°C).
Apply corrosion preventive, MIL-C-6529,
• Corrosion preventive, MIL-C-6529, is Type III, to the bearings before heating
toxic to skin, eyes, and respiratory tract. and after they have cooled to room tem-
Skin, eye, and respiratory protection is perature.
required.
NOTE Heating and chilling are defined as
• Dry ice, BB-C-104: Do not let this mate- any temperature 10°F (6°C) or more above or
rial touch you. Low-temperature skin below room temperature.
damage. Can decrease available air.
Asphyxiant. Personal protective equip- a. When it is necessary to chill a bearing in
ment required, especially insulated dry ice, coat the bearing thoroughly with
gloves and eye protection when han- corrosion preventive, MIL-C-6529, Type
dling material. Use in a well-ventilated III, and place in a plastic bag prior to chill.
area.
• Use thermal gloves when you move or b. Immediately after installation of a chilled
touch hot or cold parts. Hot or cold bearing, apply heat with a heat gun until
parts can cause injury. bearing and adjacent parts are brought to
room temperature. Remove any moisture
• When using compressed air for clean- using clean, dry shop air, and coat
ing, cooling, or drying, do not exceed 30 the bearing with corrosion preventive,
psig. Wear eye protection and do not MIL-C-6529, Type III.
direct compressed air at self or others.
11-30 Change 6
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
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c. Heat bearings using ovens or heat guns. CAUTION Do not repair titanium parts
No direct heat source, such as a blow with tools, such as grinding wheels, files,
torch, may be used. When the bearing stones, or emery cloth, that have been used to
returns to room temperature, coat with cor- repair other types of metal. Damage to parent
rosion preventive, MIL-C-6529, Type III. metal could occur.
11-3.21 Spray Shields • Defects more than 0.25 inch (6.4 mm)
apart shall be blended separately. Those
Spray shields shall be positioned on tubing so less than 0.25 inch (6.4 mm) apart (except
as to prevent fluid from spraying on the engine splines) shall be blended together. Splines
if a leak occurs at the shielded area of a tube. that are closer together than 0.25 inch
(6.4 mm) and defects shall be repaired sep-
11-3.22 Blending arately.
NOTE Refer to specific engine manual sec- • The finish on the blended area must be as
tion or service bulletin for blend limits for the close as possible to the original finish of
piece part under review. Use the limits in this the part.
procedure only when no specific limits are 11-3.22.2 Hand Blending
specified for the component in the engine man-
ual or appropriate service bulletin. Sharp edges can be blended out using abrasive
stones or papers, files, or crocus cloth. Coarse
Blending is a repair procedure that is used to grades of abrasives or files may be used for
remove stress concentrations caused by nicks, fast metal removal, but the parts must then be
scratches, or other sharp-edged damage marks given a smooth surface finish with fine grades
on critical parts. Removal of the material sur- of abrasives or crocus cloth.
rounding the stress concentration, so that the WARNING Do not breathe the particles
sharp edges are blended into smooth contour,
from grinding or let the particles touch you.
relieves the stress concentration and permits The particles can cause damage, injury, or
further use of the part by lessening the danger irritation to you. Use personal protection
of cracking. equipment. Use local mechanical exhaust
ventilation or an approved respirator.
Blending is also used to remove sharp edges
resulting from machining, drilling, etc., and to NOTE Refer to the inspection and repair lim-
restore the original contour and/or surface fin- its for specific instructions on blending limits
ish to parts that have been repaired by weld- applicable to each part of the engine.
ing, brazing, etc.
a. When blending compressor rotor blades,
11-3.22.1 Blending General Practices stator vanes, turbine blades, and similar
parts, blend in a radial direction in relation
The following rules for blending shall be
to the engine. Avoid removing metal from
observed, unless specific instructions to the
leading and trailing edges of airfoil sec-
contrary are given in the text:
tions in such a way that the edges become
thin or sharp; blend so as to maintain
approximately the original contour.
Change 6 11-31
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
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Volume I GE Industrial AeroDerivative Gas Turbines
b. When blending a cylindrical part, blend in a. Rough out defects using coarse grades of
a circumferential direction, not along the resilient flexible abrasive impregnated
axis of the part. wheels, brushes, or points. Use fine or
extra fine grades to finish the blend areas.
c. The finish on the blended area shall be as
close to the original finish as possible. b. Follow the requirements described-in
d. When blending on a part involving a paragraph 11-3.22.2 when doing power
radius, keep the radius as specified in the blending.
repair section. If the radius is not speci-
c. Etch reworked area per paragraph 11-3.23
fied, keep it as close as possible to the
and inspect by spot fluorescent-penetrant
original contour. Refer to a similar part, if
method, per paragraph 11-3.24, after
necessary, to determine original radius.
blending.
e. Etch reworked area per paragraph 11-3.23
11-3.22.4 Component Specific
and inspect by spot fluorescent-penetrant
Requirements
method, per paragraph 11-3.24, after
blending. NOTE Requirements in specific engine man-
11-3.22.3 Power Blending ual section or appropriate service bulletin take
precedence over the following procedures. The
Blending on most parts may be done by using requirements in this section should be used
a power-driven polishing wheel or rubber- with engine manual or service bulletin criteria
bonded abrasive points, and any special or when no criteria are specified.
instructions for the individual part must be fol-
lowed. a. Blending Airfoils.
WARNING Do not breathe the particles (1) The types of airfoil damage described
from grinding or let the particles touch you. below may be repaired by hand blend-
The particles can cause damage, injury, or ing or by power blending. Always
irritation to you. Use personal protection refer to applicable part inspection
equipment. Use local mechanical exhaust paragraph for a description of airfoil
ventilation or an approved respirator. defect limits as follows:
CAUTION Power blending of airfoil sec- (a) Nick – A V-shaped depression in
tions may be done only when specified by
the airfoil made by a sharp-edge
individual part instructions. When doing
object pushing the metal inward.
power blending, be sure to avoid building up
excessive heat and resulting thermal stresses (b) Pit – A round sharp-edged hole
in the part. with a rounded bottom caused by
NOTE After power blending of a titanium corrosion.
part is completed, hand-blend the same area
approximately 0.002 inch (0.05 mm) deeper to (c) Scratch – A V-shaped line or fur-
remove any residual stresses in the surface row in the airfoil such as would
material. be made by dragging a sharp
object across the surface.
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(d) Dent – A smooth rounded depres- (c) Defects more than 0.25 inch
sion in the airfoil made by impact (6.4 mm) apart shall be blended
with a rounded object. If there is separately; those 0.25 inch
any noticeable sharp discontinu- (6.4 mm) or less apart may be
ity in the depression, it should be blended together. All blends must
considered as a nick. Waviness of have a minimum radius of
leading or trailing edges is to be 0.25 inch (6.4 mm). The total
treated as a dent. reduction in chord width may be
taken on either side or divided
(e) Erosion – A sand- or shot-blast- between the sides. The amount of
ing effect on the leading edges or rework is controlled by the mini-
the leading portion of the con- mum chord width limit. The min-
cave side caused by sand or dust imum allowable chord is given
going through the engine. for root and tip of airfoil, the min-
imum chord at other points is
(f) Torn Metal – A separation or proportional. To minimize the
pulling apart of material by force, possibility of an engine stall,
leaving jagged edges. keep the shape of the blended air-
foil leading edge as close as pos-
(2) Hand-blending of airfoils may be sible to the original contour (see
done as specified below: figure 11-12).
(a) Blending is done to remove stress (d) Blending limits are given as
caused by nicks, pits, and depth dimensions to make it eas-
scratches to prevent blade failure. ier to see how much can be
Remove high metal and repaired. Experience has shown
straighten dents (where permit- that depth limits are used for
ted) to restore the airfoil shape as most rework. However, the mini-
closely as possible to its' original mum chord limit is the most
aerodynamic contour. important dimension; it should be
checked in borderline cases or
(b) Blending shall be finished with
where previous rework is evident
fine stone or crocus cloth.
in the same area. For conve-
Coarser tools may be used for ini-
nience, the depth limits and mini-
tial removal of material. Finish
mum chord limits are given in
blending in a direction along the
both decimals and fractions. In
length of the blade or vane and
borderline cases where depth lim-
remove all evidence of marks
its and minimum chord limits
across the airfoil that may have
conflict with one another, use the
been made during initial blend-
decimal minimum chord dimen-
ing.
sion to decide if the part is usable.
11-12
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Figure 11-12 Airfoil Leading Edge Blending
(e) Defect limits are given as depth on penetrant where air passages
dimensions since this is the are present to prevent excessive
dimension that affects strength. penetrant entrapment.
However, accurate depth mea-
surements require special equip- (3) Power-blending of rotor blades, vari-
ment not normally available. able vanes, and vane segments may be
Comparing the depth of a defect done as follows:
with the thickness of a leaf of
thickness gage or with the thick- (a) To avoid damaging the airfoil,
ness of a piece of safety wire is a use masking tape and mask off
reasonably accurate way of mea- the airfoil next to the rework area.
suring depth (see figure 11-13).
(b) Use coarse grade, silicon-carbide
11-13 impregnated rubber wheels and
(f) Swab etch reworked area per
points for the initial benching of
paragraph 11-3.23 and spot-fluo-
the blades and vanes.
rescent-penetrant inspect per
paragraph 11-3.24. Brush or swab
11-34 Change 6
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Figure 11-13 Airfoil Defect Measurement
NOTE During finish blending of defects, (f) Carefully inspect the blades and
make a radius on both the leading and trailing vanes.
edges of the airfoil. To do this, apply light
pressure with the rubberized abrasive wheel, b. Blending Minor Indications in Tubing.
and let the cushion action of the wheel do both
(1) Use a fine abrasive stone, a small file,
the blending of the radius and the buffing of
emery cloth, or crocus cloth for blend-
the defect.
ing.
(c) Finish blending the defects, using (2) Blend around the circumference of the
the fine and extra fine grade of tubing. The finished blend shall be as
rubberized abrasive wheels. close as practical to the original finish
Remove only enough material to of the part.
repair the defect.
c. Removing High Metal. High metal is
(d) Swab etch reworked areas per caused by the displacement of metal above
paragraph 11-3.23 and spot-fluo- a surface. It is found around defects like
rescent-penetrant inspect per nicks and scratches. Remove high metal as
paragraph 11-3.24. follows:
(e) Place the repaired blades and (1) Use a fine abrasive stone, a small file,
vanes in separate containers to emery cloth, or crocus cloth to
prevent damage during handling. remove high metal.
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(2) Remove only the material that is pro- WARNING Etching solution contains acid
jecting above the original surface con- and is highly toxic to skin, eyes, and respi-
tour (see figure 11-14). ratory tract. Skin and eye protection, and
vapor control are required. Avoid all con-
(3) Swab etch reworked area per para- tact.
graph 11-3.23 and spot-fluorescent-
penetrant inspect per paragraph 11- CAUTION Refer to the Material Safety
3.24. Data Sheets (MSDS) for storage and han-
dling instructions for etchant solution.
11-3.23 Swab Etching Procedure Etchant solutions can become hazardous to
personnel if not handled appropriately.
This procedure describes the materials and
process for swab etching used as a preliminary a. All surfaces to be etched must be free from
step before fluorescent-penetrant inspection. oil, grease, scale, or other extraneous
Etching solutions are used as described herein material.
or with exceptions as specified for individual
parts in the Shop Manual. 11-14
Figure 11-14 Blending and High Metal Removal
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b. Pour a small quantity of stock solution into 11-3.24 Spot-Fluorescent-Penetrant
a clean plastic beaker or dish. This quan- Inspection
tity will be the working solution, and is not
to be returned to the stock bottle. The spot-fluorescent-penetrant inspection pro-
cess is intended for inspections at remote loca-
c. Saturate a cotton swab with the working tions. It is a localized process, limited to small
solution, and swab the surface to be etched specific areas for inspection. It is not intended
for 60-90 seconds, all Classes, except as a substitute for normal inspection. It is con-
Class G. Class G etching time is 3-4 min- venient to use for inspection of welded or
utes. (Refer to MSDS for classification of other localized repair areas.
etchant being used.) Keep the etching
solution within defined boundaries of the Personnel performing this inspection must be
area to be etched. Masking may be certified in accordance with MIL-STD-410,
required to contain etchant to areas for American Society of Non-Destructive Testing
etching. (ASNT-TC-IA), Air Transport Association
Specification No. 105 (ATA 105), or locally
NOTE Keep fresh solution in contact with the approved certification program.
metal surface at all times by dipping the swab
into the working solution periodically. Rub the Any training which may be provided by GE
swab continuously over the surface of the for a technique requiring the performance of
metal being etched, to prevent the formation of this inspection method does not imply that the
an inert sludge. personnel who receive that training have met
the requirements for inspector certification in
d. After etching, blot up etching solution accordance with MIL-STD-410, ASNT-TC-
from the metal surface with a clean paper IA, or ATA 105.
towel or cloth.
11-3.24.1 Spot-Fluorescent-Penetrant
e. Gently wipe the etched area at least three Inspection Equipment/
times with a cloth or paper towel saturated Materials
with clean water. Blot dry with clean cloth
or paper towel. a. Equipment required:
CAUTION Do not pour working solution (1) Inspection booth, darkroom, or black
back into stock container. Although the small cloth hood (for remote locations) to
quantities involved do not ordinarily consti- prevent excessive admission of white
tute an environmental hazard, flush away light.
discarded solutions with several volumes of (2) Compressed air supply for drying
water to ensure adequate dilution. parts. Air supply must have filters to
remove oil and moisture which can
f. Discard used working solution, rinse, and contaminate parts or inspection mate-
dry plastic container for future use. rials.
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(3) Ultraviolet lamp to detect fluorescent (4) Non-Aqueous Wet Developers
indications. The ultraviolet (black) (NAWD): ZP9B, C, E, F, or D499C
light source used for the detection of (Magnaflux Corporation)
fluorescent indications shall have an
intensity no less than 1,000 micro- (5) Halogen-free solvents: Isopropyl
watts per sq. centimeter when mea- Alcohol (TT-I-735) or Acetone
sured at 15 inches. (381.0 mm). The (O-A-51)
black light should be checked on a
weekly basis or before use, whichever 11-3.24.2 Spot-Fluorescent-Penetrant
is less frequent. Inspection Procedure
(4) White light lamp for visual inspection This procedure is to be used wherever the
of parts. shop manual calls out specific classes using
either waterwashable or post-emulsifiable
(5) Time piece for timing operations. penetrant systems.
(6) Tools for inspection personnel:
NOTE
(a) Three power and 10 power mag- • If visible color dye penetrant has been
nifying lenses used on parts which are to be subsequently
(b) Cotton swabs or small fine hair inspected with fluorescent penetrants, the
art brush to apply solvents for contamination by the dye may prevent reli-
evaluating questionable indica- able fluorescent penetrant inspection. Any
tions color dye indications evident by white
light visual inspection shall be considered
b. Materials required: valid indications even if not detectable by
ultraviolet light.
NOTE Qualified Products listed in MIL-I-
25135 QPL (Qualified Products List) as Level • Excessive white light may interfere with
3, Method D, are considered acceptable alter- detection of a rejectable size indication. A
nates to the products listed. test part having a known defect can be
used to evaluate effectiveness of white
(1) Post-Emulsification Fluorescent-Pen- light shielding.
etrant Oils: ZL22A, B, or C, ZL27 or
ZL27A (Magnaflux Corporation) a. Parts must be cleaned of all traces of oil,
grease, carbon, and rust scale prior to pen-
(2) Hydrophilic Removers: ZR10A or etrant application.
ZR10B (Magnaflux Corporation)
b. Apply penetrant oil with soft-bristle brush,
(3) Dry Powders: ZP4A or ZP4B cotton swab, or spray application. Allow a
(Magnaflux Corporation) minimum of 30 minutes for penetration.
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WARNING onds contact time. If remover is
applied manually, do not scrub the
• Acetone, O-A-51: Explosive. Flamma- surface of the part with the applicator.
ble. Avoid sources of ignition, sparks, or Use applicator only to deliver fluid to
flames. Do not inhale, ingest, or let this the part surface.
material touch you. Asphyxiant. Central
nervous system damage/adverse effects. WARNING Nonaqueous developer is
Liver and kidney damage. Allergen. mixed in a solvent base containing acetone
Irritant. Personal protective equipment or isopropyl alcohol. Solvents are flamma-
required. Do not use in an enclosed ble and toxic to skin, eyes, and respiratory
space. Use in a well-ventilated area or tract. Skin, eye, and respiratory protection
with local mechanical exhaust ventila- is required. Avoid repeated or prolonged
tion - if not available, use an approved contact. Avoid breathing vapors and use in
respirator. a well-ventilated area.
• Alcohol is flammable and toxic to skin, d. Apply either dry powder or NAWD as a
eyes, and respiratory tract. Skin and eye fine thin coating at ambient temperature to
protection is required. Avoid repeated a dry surface. Allow a minimum of 10
or prolonged contact. Use in a well-ven- minutes for developer to absorb penetrant
tilated area. before inspecting part.
CAUTION Titanium alloy parts are subject e. Evaluate any indication to the required
to stress corrosion cracking when residues of inspection standards.
halogen containing compounds remain on a
part that is subsequently subjected to elevated f. Remove all residues by spraying, wiping,
temperatures typical of welding, heat treat- or soaking with approved solvents.
ing, or engine operation. These parts must be
thoroughly cleaned with nonhalogen com- 11-3.25 Miscellaneous Procedures
pounds after exposure to any halogen con-
CAUTION Use of motor-driven hydraulic
taining compound to prevent the cracking
pumps to operate hydraulically actuated spe-
and possible failure of parts.
cial support equipment other than torque
NOTE Indications of defects can be lost by multipliers is not recommended. Equipment
use of excessive solvent. damage can result from improper power
application.
c. Wipe off excess penetrant with a clean
cloth using a solvent. a. Use hand-operated hydraulic pumps to
operate hydraulically actuated special sup-
(1) Alternate. Remove excess penetrant port equipment such as pushers or pullers,
with a hydrophilic remover, provided unless otherwise specified.
it belongs to the same family as the
penetrant used. Do not exceed 90 sec-
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b. Exercise extreme care during assembly or i. When installing or removing body-bound
disassembly operations to prevent bolts, tap them straight through the holes.
entrance of pieces of safety wire, nuts, Do not turn them.
washers, or any other objects into the
engine or assembly. If anything is dropped j. Verify identification of all mating parts.
into the engine during assembly or disas-
sembly, stop and remove the object before k. Observe tagged parts for proper location.
proceeding.
l. During assembly, align matchmarks on all
c. Do not store tools or maintenance equip- parts that were marked during disassem-
ment on or against the engine. Account for bly.
and properly store all tools after use.
m. Keep all protectors, plugs, and caps
d. Clean fittings of contamination before installed until removal is required.
making or breaking connections.
n. Prior to final assembly, inspect all cavities
WARNING Do not use external engine pip- and openings for foreign material.
ing as a ladder or hand-hold while perform-
o. Inspect all mating flanges for foreign
ing maintenance. Serious damage or
material prior to final assembly. Remove
personal injury could result. Use only
any high metal with a fine stone.
authorized work stands and platforms.
CAUTION Do not mix plated hardware with
e. Handle all parts carefully. Lift heavy parts
unplated hardware. Do not use silver or cad-
with proper lifting fixtures and a hoist to
mium-plated tools or hardware on titanium
prevent damage to parts and physical harm
parts. Plating contains small quantities of
to personnel.
chlorine salts that are harmful to titanium.
f. Always use fiber or plastic blocks and
p. Three types of tools (common, impro-
hammers with plastic, rawhide, or nylon
vised, and special) are used to perform
heads for driving operations.
maintenance. Common tools are identified
g. Tie related parts together when they are only when used in special applications.
removed. Tag or mark parts for identifica- Drawings for improvised tools are incor-
tion. porated in the text when such tools are
quired. Special tools are identified both by
h. Coat parts, that are to be stored for any name and part number when they are
length of time, with an appropriate preser- required.
vative.
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WARNING Lubricating oil, MIL-PRF- place or temporarily reinstalled until the
23699F (C/I): Combustible. Do not inhale, replacement component is installed.
ingest, or let this material touch you. Irri-
tant. Personal protective equipment w. Parts or assemblies designated as matched
required. Use mechanical exhaust ventila- sets elsewhere in this manual or by the
tion - if not available, use an approved res- parts list shall be maintained as a matched
pirator. set throughout the maintenance cycle. Set
numbers, part numbers, and serial num-
CAUTION Engine lubricating oil may bers shall be protected during cleaning or
soften paint or stain clothing. Clean spilled repair to prevent removal. When identifi-
oil from painted surfaces. cation is removed, or is no longer legible,
the item shall be re-marked per the origi-
q. Accessories, tubes, and hoses may have oil nal marking method and location for the
or fuel in them at time of removal. Drain part.
these fluids from accessory being removed
and cap all connecting hoses or tubes. x. When discrepancies are found during
maintenance, refer to inspection tables for
r. Lubricate all gears and splines with engine limits and corrective action.
lube oil before installing them, unless oth-
erwise specified. Petrolatum, Fed Specification VV-P-236, shall
be used as an assembly aid for tight-fitting
s. Prior to the installation of any part, a parts, bearings, and packing, unless otherwise
visual check should be made and any obvi- specified.
ous signs of handling damage or abnormal
wear should be noted and reported so that NOTE Mobile Assembly Fluid 403C may be
corrective action can be taken. used in place of soft petrolatum.
t. Always read the complete operation and 11-3.26 V-Band (Coupling) Clamps
be sure you understand it fully. It is better
to stop and ask than to continue and cause 11-3.26.1 Preinstallation Checks
unnecessary work and/or damage.
a. Check alignment of tube ends, unre-
u. Do not disassemble any component any strained, to the following maximum limits
further than necessary to perform the prior to installing V-band clamps:
required maintenance, even though com-
plete disassembly instructions may be (1) Parallelism: no angle (centerlines of
given. Remove piping and electrical leads tubes or fittings parallel).
only as required to perform maintenance
(2) Offset between fittings or tube center-
tasks.
lines: no more than 0.060 inch (1.52
v. Attaching hardware (bolts, nuts, plain mm) circumferential, axial, or com-
washers, brackets, clamps, etc.) is gener- bined.
ally reusable. When possible, it is recom-
(3) Gaps: no more than 0.060 inch
mended that attaching hardware be left in
(0.15 mm) space between fitting
seats.
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(4) If tube ends do not align within the for tool marks and cracks. V-band cou-
above limits, readjust mounting until plings in poor condition should be
proper alignment is attained. replaced.
b. Ensure flange faces are free of dirt, grease, f. Check the threads on the T-bolt for wear
corrosion, distortion, deformation, and and condition. If there is any sign of wear,
scratches. galling, or deformation, install a new T-
bolt or coupling clamp.
c. Use protective flange caps on the ends of
all ducts until the installation progresses to g. Check the T-bolt for straightness; how-
the point where removal of the cap is ever, if it is bent it will be necessary to
essential to continuing with the installa- determine if the bend is intentional. Some
tion. small diameter couplings have curved T-
bolts. Check the applicable illustrated
d. Use care during the installation of ducts parts breakdown for part identification. If
and tubes to ensure mating and alignment in doubt, install a new T-bolt or coupling
of flanges. A poorly fitted joint requires clamp.
excessive torque on the T-bolt to close the
joint and imposes structural loads on the h. Check the trunnion and latch for freedom
V-band clamp. Adjacent support clamps or of movement or other overloading.
brackets should remain loose until installa-
tion of the coupling has been completed. i. Avoid twisting, spreading, or bending of
When connections are by V-band cou- the coupling when positioning the cou-
plings, the weight of the components pling on the joint.
should be fully supported during the fit-up
and installation of the couplings. j. When gaskets are used in the joint, exer-
cise care in handling to avoid nicks and
e. When reinstalling a used coupling, check burrs on the gasket surfaces. Whenever a
it for twist or distortion. Visually check the joint is disassembled after service opera-
V-section for spreading at the open ends or tions, a new gasket should be used when
other signs of distortion. Check spot welds reassembling to ensure maximum sealing
or rivets for condition and security. The efficiency. Exercise care to ensure that the
corner radii should be carefully checked gasket is properly seated.
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11-3.26.2 Installation b. Install gasket, if required, and mate both
flanges.
The following procedures should be followed
to ensure proper V-band clamp installation: c. Relocate clamp over both flanges and
press clamp closed.
CAUTION
d. Install nut. Ensure T-bolt is properly
• Do not use pliers on V-band clamps to seated, and tighten nut to approximately
force alignment of tube ends while one-half of required torque marked on
engaging V-band bolts and nuts. Residual strap.
stress in the tubes and nicks, scratches, or
deformation in the clamps, can cause e. Tap clamp lightly around circumference
premature failure of these parts. with a rubber mallet to equally distribute
load.
• Coupling T-bolt nuts shall not be reused.
Do not substitute any other coupling nut f. Alternate tightening and tapping until
for the type nut supplied with the cou- torque stabilizes at the specified value.
pling. The correct nut (ESNA Z1200J Avoid overtorquing.
series) is identified by the letter “J”
stamped on a wrench flat. Failure to com- g. Inspect clamp for even seating.
ply may result in duct joint failure.
h. See figure 11-15 for safety wiring the
a. Place the V-band clamp over one of tube V-band clamp. Use 0.041-0.051-inch
ends far enough to clear flange. (NOVN) (1.0-1.3 mm) safety wire.
11-15
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Figure 11-15 V-Band Clamps and Safety-Wiring Techniques
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4 CHAPTER 12
Preventive Maintenance
12-1 Purpose and Scope 12-2.1.2 Form of Inspection Tables
This chapter defines the requirements and Inspection tables in this technical manual gen-
frequency for performing preventive erally treat each component as a separate item
maintenance checks, inspections, and in order to provide the maximum amount of
servicing. Dry motoring procedures, generally information. Inspection and repair information
associated with maintenance, are also contained in tables is often revised as experi-
provided, as are definitions of terms used to ence gained through increased service time of
evaluate equipment condition and damage equipment. An explanation of table headings
during inspections. follow:
12-2 General Checks and NOTE The terms On-Site Maximum Service-
able Limit, On-Site Maximum Repair Limits
Inspections and On-Site Corrective Action apply only at
the level of maintenance at which inspection is
This section provides general guidelines, con- being conducted. For example, corresponding
ditions, and definitions for conducting engine entries of “Not repairable” and “Replace
checks and inspections. part” respectively in the On-Site Maximum
Repairable Limit and On-Site Corrective
Preventive maintenance and servicing inspec- Action columns in the maintenance inspection/
repair tables shall be interpreted as not
tions and checks are performed to reduce repairable at this level of maintenance.
unscheduled shutdown time. If the frequency Replaced part may be repairable at next
of inspection/service requires change, coordi- higher level of maintenance.
nate with the packager. Table 12-1 lists checks
and service intervals. For terminology and
Observed Defines given areas of a part
definitions, refer to table 12-2.
Condition/ with associated conditions/
Discrepancy discrepancies which may be
12-2.1 Use of Inspection Tables and Column observed.
Instructions
12-2.1.1 Extent and Methods of
Inspection
Damage can be evaluated only by thorough
inspection. Inspection for defects shall be
visual, without aid of magnification or the use
of special processes such as fluorescent pene-
trant or magnetic-particle, unless otherwise
specified at the beginning of each inspection
table.
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NOTE The on-site maximum serviceable 12-3 Motoring
inspection limits are set with the expectation
that the engine can continue in service to next Although not required as part of normal start-
inspection: 4000 hours, 450 fired starts, or ing procedures, wet and/or dry motoring is fre-
annually, whichever comes first. It does not
mean it will always be serviceable at the next quently used following maintenance to check
inspection. It is possible the condition will the engine before making a start. Wet motor-
progress in 4000 hours to be unserviceable, ing (liquid fuel only) is performed with the
but unlikely the progression will result in an fuel metering valve (FMV) open and the fuel
unscheduled event within the inspection shutoff valve open. Dry motoring is performed
period. with both the FMV and the fuel shutoff valve
closed.
On-Site Defines maximum departure
Maximum from manufacturer’s estab- 12-3.1 Dry Motoring
Serviceable lished new equipment stan-
Limit dards that will not materially Any dry motoring check should be made with
Column reduce usability of part, or that the ignition system deenergized.
will have no significant bearing
on effective use or operation of
a. Check all switches and interlocks for
equipment between scheduled
maintenance intervals. proper motoring settings.
b. With the fuel shutoff valves closed, acti-
On-Site Defines extent of repair that
Maximum can be performed on part to vate the motoring or start sequence and
Repairable return it to a serviceable condi- allow the engine to motor to maximum
Limit tion. If there is no entry in this motoring speed for 30 seconds. Observe
Column column it does not mean that and record the following:
part cannot be repaired, but
that to date, no repair proce- • Engine high pressure rotor speed
dure has been established. If
the phrase “Not repairable” is
• Starter air or hydraulic inlet pressure
entered in this column, it means
that no repair is feasible and
that no attempt should be made • Inlet air temperature
to repair it under any circum-
stances, at the level of mainte- • Lube supply pressure
nance for which inspection/
repair table is applicable. c. Deenergize the starter.
On-Site Defines if part should be
Corrective replaced, or denotes paragraph
Action in which corrective action is
Column described. If repair materials
are not available, or if part to be
replaced is not available, it is
permissible to replace next
higher assembly.
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12-3.2 Wet Motoring (Liquid Fuel Only) c. Close fuel shutoff valve and continue
motoring for 5 minutes to purge the enclo-
Any wet motoring check should be made with sure/engine fuel system of fuel. If an
the ignition system deenergized. engine start is to be made, wait a minimum
of 2 minutes before initiating the start
CAUTION cycle.
• Excessive wet motoring can result in sat- d. Deenergize the starter.
uration of the TRF insulation blankets
with fuel. 12-4 Rigging and Idle Checks
• Be certain that checklists have been
12-4.1 Rigging Checks
established for packager-furnished
equipment. Consult the packager's man- In addition to the preventive maintenance and
ual for mandatory prestart procedures servicing checks listed in table 12-1, any vari-
and make certain that the packager-fur- able–geometry system (variable inlet guide
nished lube supply subsystem is activated vane [VIGV], variable bypass valve [VBV],
and operational prior to any motoring or or variable stator vane [VSV]) that has had
start sequence. maintenance performed on it since the engine
was last operated, should undergo a rigging
a. Check all switches and interlocks for
check. Rigging check procedures are
proper motoring settings.
described in WP's 1113 00, 1312 00, and
b. With the fuel shutoff valves closed, acti- 1411 00 in Volume I of this manual.
vate the motoring or start sequence and
allow the engine to motor to maximum
motoring speed for 30 seconds. At maxi-
mum motoring speed, open the fuel shut-
off valves. Observe and record the
following:
• Engine high pressure rotor speed
• Starter air or hydraulic inlet pressure
• Inlet air temperature
• Lube supply pressure
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12-4.2 Idle Checks NOTE See appropriate packager's manual
for additional cautions and inspections.
Idle power functional checks are usually per-
formed following any maintenance on the a. With the engine operating at idle, permit
engine, lube, or fuel systems that involve the speed to stabilize for 2 minutes.
breaking of connections, the separation of
flanges, or any action that could possibly b. Deactivate the enclosure fire extinguishing
affect operation of the gas turbine system. Idle system. Open enclosure access door. Turn
checks should be performed as follows: off enclosure secondary ventilation sys-
tem, if applicable.
WARNING When entering the gas turbine
enclosure, the following requirements shall c. Station personnel outside the enclosure as
be met: a safety measure before permitting entry to
the enclosure.
• The gas turbine shall be shut down.
d. Wear ear protection and thermally insu-
• Module entry during engine operation lated gloves when entering the enclosure.
is prohibited in general. If entry should
be required during engine operation, e. Make a thorough inspection of the entire
contact GE Field Service for a represen- gas turbine system and correct all discrep-
tative who is trained to enter the module ancies before continuing operation.
under such conditions.
f. Exit the enclosure and close the access
WARNING The fire extinguishing system door.
must be deactivated before personnel enter
the enclosure. Suffocation can occur if the g. Reactivate the enclosure fire extinguishing
fire extinguishing system is activated. system and secondary ventilating system,
if applicable.
WARNING The following steps must be
performed before entering the enclosure. h. Accelerate to the desired power level.
These conditions must be maintained while Observe all operating limits specified in
inside the enclosure to prevent injury to Chapter 8.
personnel.
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Table 12-1 Preventive Maintenance and Servicing Checks
Maintenance Interval:
4000 Operating Hours,
450 Fired Starts,
or Annually (whichever Procedure
Maintenance Item (Note 1) comes first) Reference
Borescope Inspection X and (Note 5) WP 4015 00
Inlet and Coupling Inspection X and (Note 4 and 5) WP 4010 00 and Packager's
Manual
Enclosure Inspection X and (Note 4 and 5) Packager's Manual
External Engine Inspection X and (Note 4 and 5) WP 4012 00
Lube and Scavenge Pump Inlet Screen and X and (Note 5) WP 4020 00
Filter Inspection
GT Starter Oil Return Line Screen Inspection X and (Note 5) Packager's Manual
(If installed)
Lube Oil Test X and (Note 5) WP 4016 00
Chip Detector Check X and (Note 4 and 5) WP 4017 00
Liquid Fuel Nozzle Inspection X and (Note 3, 4 and 5) TS-48, Chapter 10
On-Engine Liquid Fuel Filter Service X and (Note 3, 4 and 5) WP 4018 00
Inspection
Variable Inlet Guide Vane Rig Check X and (Note 5) WP 1113 00
Inspect shims for proper
clearance
Variable Stator Vane Rig Check X and (Note 5) WP 1411 00
Variable Bypass Door Rig Check X and (Note 5) WP 1312 00
Variable-Geometry System Filter Check X and (Note 5) WP 4021 00
Ignition System Functional Check X and (Note 5) WP 4023 00
Igniter Plug Inspection X and (Note 4 and 5) WP 1516 00
T48 Thermocouple Inspection X and (Note 4 and 5) WP 1711 00
P48 Inlet Probe Inspection X and (Note 4 and 5) WP 1712 00
Fuel Metering Valves - Functional Check X and (Note 5) Packager's Manual
Fuel Shutoff/Bleed Valves - Functional Check X and (Note 5) Packager's Manual
Fuel/Purge and Solenoid Valves System X and(Note 5) Packager's Manual
Check
Compressor Cleaning (Water-Wash) As required to meet WP 4014 00
performance objective
Vibration Monitoring System Check X and (Note 4 and 5) WP 4024 00
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Table 12-1 Preventive Maintenance and Servicing Checks (Continued)
Maintenance Interval:
4000 Operating Hours,
450 Fired Starts,
or Annually (whichever Procedure
Maintenance Item (Note 1) comes first) Reference
Exhaust and Coupling Inspection X and (Note 4 and 5) WP 4013 00
Stage 1 HPC Blade Replacement (systems Every 16,000 hours of WP 2413 00
with HPC SPRINT® only) SPRINT® operation
Stage 2, 3, and 4 HPC Blade Chord Length At same time as stage 1 HPC WP 2413 00
® only) blade replacement
Inspection (systems with HPC SPRINT
Stage 1 HPC Blade Replacement (systems Every 16,000 hours of HP WP 2413 00
with LPC + HPC SPRINT® only) ®
SPRINT operation or 25,000
hours of total SPRINT®
operation, whichever comes
first
Stage 2, 3, and 4 HPC Blade Chord Length At same time as stage 1 HPC WP 2413 00
Inspection (systems with LPC + HPC blade replacement
SPRINT®)
Stage 0 and Stage 1 LPC Blade Inspection Every 25,000 hours of (LP) WP 4015 00
SPRINT® operation
Redundant Overspeed System Check X & (Note 6) Packager's Manual
SPRINT® Nozzle Clean, Flow, and Inspection Every 25,000 hours of WP 1916 00
at Authorized Repair Source SPRINT® operation
High Pressure Compressor Stages 3, 4, and 5 Every 12,500 hours WP 1412 00
Variable Stator Vane Bushing Replacement
NOTES:
1. Inspections within the enclosure shall not be made with engine operating above idle speed.
2. Semiannual inspections shall be made with the engine shut down.
3. Change on-engine liquid fuel filter element whenever a 5-7 psi filter ΔP is noted on user gage.
4. Inspections shall be made anytime maintenance is performed in the area or when the area is
accessible.
5. Inspections shall be made as required per troubleshooting procedures.
6. Semi-annually test the redundant overspeed protection system to verify its function using a
simulated speed signal input.
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Table 12-1A. Recommended Preventive Maintenance and Servicing Checks
Maintenance Item (Note 1) Maintenance Interval Procedure Reference
Starter Carbon Seal Cleaning Annually WP 2813 00
D-sump/E-sump Drain Interface Annually N/A
Cleaning (disconnect package
drain to clean engine and package
drain as required)
Fuel Nozzle Clean, Flow, and At Hot Section Interval WP 1510 00,
Inspection at Authorized Repair WP 1511 00,
Source WP 1512 00,
WP 1513 00 or
WP 1514 00
Hydraulic Starter Spline Lubrication Annually WP 1815 00
Table 12-1B. Special Inspections
Maintenance Interval:
4000 Operating Hours,
450 Fired Starts,
or Annually (whichever
Maintenance Item (Note 1) comes first) Procedure Reference
High Pressure Turbine Diffuser X (Until Service Bulletin Service Letter
LM6000-IND-0216 LM6000-03-06 R1
is incorporated)
Inlet Gearbox Spline X Service Letter
LM6000-04-01 R2
High Pressure Compressor X Service Letter
Stage 11 Manifold Check Valve LM6000-04-02
Right Side Aft Stage 8 LPT Cooling X (Until Service Bulletin Service Letter
Air Tube LM6000-IND-0211 is incorpo- LM6000-04-03
rated)
Igniter X (Until Service Bulletin Service Letter
LM6000-IND-0219 is incorpo- LM6000-04-06 R1
rated)
VBV Clevis Bolt Thread Engage- X Service Letter
ment to Locking Nut LM6000-04-07
PCC Forward Mount Bolt Wear X Service Letter
LM6000-01-03
NOTES:
1. Inspections shall be made with the engine shut down.
2. Change filter element whenever a 5-7 psi filter ΔP is noted on user gage.
3. Inspections shall be made anytime maintenance is performed in the area or when the area is accessible.
4. Inspections shall be made as required per troubleshooting procedures.
5. Test the redundant overspeed protection system to verify its function using a simulated speed signal input.
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Table 12-2 Definition of Terms
Manual Terms Associated Terms
Abrasion Wearing, grinding, or rubbing away of Chafing, Fretting, Rub, Scuff, Wear.
small amounts of material. Surface may be smooth or
rough.
Blister A raised portion of a surface caused by Bubble, Flaking, Oxide formation, Peeling, Scale,
separation of the outer layers of the parent material or Slag inclusion (Weld).
of a coating.
Brinell (True) Often related to ball and roller Dent.
bearings having been improperly installed or
subjected to extremely high shock or impact loads at
zero revolutions per minute. Usually occurs as a
series of shallow depressions in the load area of the
raceway.
Brinell (False) A specialized form of fretting
recognized by the occurrence of a series of shallow
indentations in the race at each roller position on the
loaded side of the bearing. Often red oxide of iron
may be found where this has occurred.
Brittle A change in the resiliency of the parent Cold-worked, Hard (like an old preformed packing—
material, usually due to aging, extreme heat, extreme ring), Stiff.
cold, chemical action, or cold-working (metal).
Buckle A large—scale deformation of the original Ballooning, Bend, Blister (incorrect: see Blister),
contour of a part, usually due to pressure or impact Bulge, Crease, Curl, Dent (not to be confused with
from a foreign object, structural stresses, excessive small area defect in heavy material: see Dent),
localized heating, high pressure differentials, or a Depression, Distortion (usually refers to heavy
combination of these. material), Elongated (usually refers to out of round),
Fold, Indentation, Kink (usually results in crack: see
Crack), Protrusion (hollow), Rupture (result of
excessive buckling), Uneven, Warpage, Wrinkle.
Bulge A raised portion or outward swelling on a Hump, Protuberance.
surface, as from pressure.
Burn A rapid, destructive, oxidizing action usually Bum out (see Missing piece), Erosion (chemical or
caused by higher temperatures than the parent grit), Guttered, Heat—check, Heat-curled, Heat
material can structurally withstand. Change in color deterioration, Hole (burn), Hot spot, Overheated,
and appearance often indicates this condition. Oxidation.
Burr A rough edge or a sharp on the edge or surface
of the parent material.
Chafing A rubbing action between parts having Abrasion, Fretting, Rub, Wear.
limited relative motion (as in vibration).
Chip A breaking away of the edge of the parent Break, Nick (similar to Chip, but no parent material is
material, usually caused by heavy impact from a removed: see Nick).
foreign object.
Coking An accumulation of carbon. Carbon buildup.
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Table 12-2 Definition of Terms (Continued)
Manual Terms Associated Terms
Corrosion The gradual conversion of material to
another compound due to chemical attack. It appears
as a mass of small pits due to the loss of the formed
compound from the affected surface which
cumulatively creates a cavity (usually shallow) in the
surface of the parent material.
Crack A parting of the parent material. Break, Crater (usually found in castings), Fatigue
damage, Fissure, Fracture, Inclusion (usually found in
castings), Lap (usually found in forgings), Rupture,
Separation, Shear (not usually considered a crack:
see Missing Piece), Slit, Tear.
Craze A mesh of fire cracks on a surface or glaze Fine cracks around bolt holes or surface edges that
defined as numerous superficial surface cracks which are subject to stresses or pressure. Fine cracks in
have no usual width or depth. metal, paint surfaces, seal edges, plastics, windows,
sight glasses, etc.
Dent A completely smooth surface depression Peen.
caused by pressure or impact from a smooth, ball—
like foreign object. The parent material is displaced,
but usually not is separated.
Deviation A condition which causes a port to differ Damage, Defect, Flow, Imperfection, Irregularity.
from the manufacturer's blueprint.
Erosion The gradual wearing away of material
caused by the hot flow of gases or foreign particles.
An eroded surface may appear similar to a corroded
surface.
Flake A thin, chiplike, or scalelike layer of metal.
Fretting Wear, in a rippled pattern, caused by Chafing, Abrasion.
friction.
Gall A defect caused by the movement of two See Pickup.
surfaces in contact with each other. In most cases an
accumulation of foreign material is deposited on the
parent material.
Gouge A wide, rough scratch or group of scratches,
usually with one or more sharply impressed corners
and frequently accompanied by deformation or
removal of parent material.
Groove A long, narrow, continuous cavity or If impression is shallow and smooth, see Wear.
impression caused by pressure of a moving surface
in contact with the parent material.
Imbalance The state of being out of balance. An un-
equal distribution of weight about the axis of rotation.
Loose Abnormal movement of a part. Backed out, Excessive movement, Excessive play,
Insecure, Leaks, Loose fit, Not tight, Not torqued,
Shakes, Sloppy, Rattles, Unbottomed, Unpinned.
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Table 12-2 Definition of Terms (Continued)
Manual Terms Associated Terms
Misaligned Mismatch or malformation of any parts Eccentric, Not axial, Not concentric, Out—of—round,
that either prevent perfect assembly or results in Unmatched, Unsquared.
faulty operation and/or ultimate part failure.
Missing Piece Removal or loss of a portion of parent Break (two or more pieces), Burn (burned away),
material due to a combination of defects or damage. Burn—out, Corrosion (eaten away), Erosion (worn
away), Guttered, Hole, Rusted (rusted away),
Sheared, Smashed, Torn (torn away).
Nick A surface impression with sharp corners or Chip (see Chip), Dent (see Dent), Notch (see Chip).
bottom, usually caused by pressure or impact from a
sharp—edged foreign body. The parent material is
displaced, but usually not is separated.
Noisy An abnormal sound condition of moving parts, Bumps (sound), Chatters, Clicks, Grates (usually
usually an increase in volume or a change of pitch. gears), Grind, Hums, Loud, RattIes (usually loose
parts), Rubs (sound of rubbing), Scrapes (sound of
scraping), Screeches, Squeals, Thumps (sound),
Whistles.
Obstructed Prevention of free flow of a fluid (air, oil, Clogged, Contaminated, Plugged, Restricted.
fuel, and water) because of foreign material in the
flowpath or malformation in the flow member.
Oxidation A surface deterioration by the chemical
reaction between oxygen in the air and the metal
surface. Attack is manifested as red rust in iron and
low alloy steels when formed at ambient temperature.
The oxides which form on superalloys are complex
and can be green or black depending on material
composition and the temperature at which it is
formed.
Pickup Transfer of one material into or upon the Burr (usually tool—rub leaving high parent material),
surface of another, caused by contact between Gall, High spot, Embedment, Inclusion (usually pick-
moving parts or deposits of molten material on a up of a dissimilar foreign material), Pile-up, Protrusion
cooler material. (deposit on parent material), Metallization.
Pinched Distortion of one or more surfaces of the Bound, Compressed, Flattened, Seized (see
parent material, caused by pressure. Seizure), Smashed (without separation into pieces),
Squashed, Squeezed, Tight.
Pit A minute depression or cavity with no sharp, Corrosion, Crater (usually in weld or casting), Dent
high—stress corners in the surface of the material. (incorrect: see Dent), Electrolytic cavity, Erosion
Pits are usually caused by chemical reaction (rusting (usually results in hole: see Burns), Fretting (see
or chemical corrosion). Wear), Inclusion (as in sand castings), Oxidation
(usually in weld), Pock—marked, SpaIled, Roughness.
Rub A surface cavity or impression caused by two If impression is shallow and smooth, see Wear. If
surfaces moving against each other. impression is sharp, see Scratch.
Scratch A long, narrow, sharp—cornered impression Abrasion, Chafe, Furrow, Groove, Rub, Scarf, Score.
caused by the movement of a sharp object across the
surface of the parent material.
Scuff A surface roughened by wear. Scrape, Scratch.
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Table 12-2 Definition of Terms (Continued)
Manual Terms Associated Terms
Seizure A welding or binding of two surfaces that Bound up, Frozen, Tight (see Pinched), Tight (fit),
prevents further movement. Wedged, Welded (without external assistance).
Sheet–Metal Dent A large—area, smooth depression See Buckle.
in the parent material.
Shingling Two adjacent surfaces overlapping when
normal position is edge—to—edge or face—to—face
contact.
Spall Broken or crushed material due to heat, Chip.
mechanical, or structural causes. Chipping of small
fragments under the action of abrasion.
Spatter A thin deposit of molten metal, usually on Splatter, Splash.
airfoil surface downstream from a burn area.
Sulfidation A form of hot corrosion in heat—resistant
alloys by the reaction at the metal surface of sodium
chloride (sea air) and sulfur (from fuel). Attack usually
occurs over a broad front and can be identified as
gray to black blisters (early stage) or surface
delamination (advanced stages).
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CHAPTER 13
Critical Parts Life Management - LM6000 PC Engine
13-1 Purpose and Scope Paragraph 13-5 defines how cycles are to be
calculated.
CAUTION
Critical life-limited parts have undergone
• Critical life-limited parts must be extensive analysis which provides a basis for
removed from service before reaching the establishing the industrial life limits defined in
declared life limit. table 13-1. GE will continue evaluating
component life limits and will revise the limits
• Serious engine damage can occur if all when technically justified.
provisions of this caution are not
complied with. The critical parts life limitations have been
substantiated based on engineering analysis
This chapter identifies specific parts of the that assumes this product will be operated and
LM6000 PC engine that are cyclic life-limited maintained using the procedures and inspec-
as a result of normal operation. Instructions tions provided in the instructions for contin-
for tracking the operating hours and operating ued operation supplied with this product by
cycles for such parts that have been identified GE, or its licensees. For Life Limited Parts
as being limited in terms of operating service, and parts that influence Life Limited Parts,
are also provided. any repair, modification or maintenance pro-
cedures not approved by GE, or its licensees,
Critical life-limited parts are those parts that,
or any substitution of such parts not supplied
should they suddenly fail, could threaten the
by GE, or its licensees, may materially affect
structural integrity of the engine or its
these limits.
package. Stress cycles on gas turbine parts
result from transients of speed and 13-2 Definitions
temperature that occur during starts,
accelerations, and decelerations. Therefore, The following terms are used in this chapter:
life limits are expressed in terms of engine
cycles and can be related to normal a. Full Cycle: A full cycle is defined as a
operational data. cycle from zero gas generator speed
with acceleration to high power
Cycles are defined in paragraph 13-2, setting, followed by shutdown of the
Definitions. Life limits of critical parts are gas turbine. High power setting is
established through analysis and testing. considered to be any power setting
Accumulated cycles are to be calculated, above synchronous idle where the
tracked, and compared to published life limits generator breaker is closed. For a
to determine when a part should be visual representation of what a typical
permanently retired from service. No LM6000 full life cycle analysis is
component shall be allowed to remain in based upon, see figure 13-1.
service beyond its published life limit.
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Figure 13-1 LM6000 Full Industrial Life Cycle
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b. Partial Cycle: A partial cycle is g. Partial Cycle Factor: Coefficient used
defined as any decrease in power as a numeric expression of the amount
(mW) greater than X percent from a of damage caused by a partial cycle
(Kp).
current steady state power (any power
setting above idle) to any controlled
h. Trip Cycle Factor: Coefficient used as
lower power setting, followed by a a numeric expression of the amount of
subsequent increase in power (>10 damage caused by a trip cycle (Kt).
percent). Steady state power is
considered to be any power setting 13-3 Affected Parts
above synchronous idle where the
generator breaker is closed. The critical life-limited parts for the LM6000
PC engine are listed in table 13-1.
• If X = 0-50, then Kp = 0
13-4 Parameters to be Tracked
• If X >50, and ≤75, then Kp = 0.1
Engine operating hours and cycles must be
• If X >75, and ≤100, then recorded and tracked for each critical life-
Kp = 0.75 limited part. Each part is uniquely identified
by the combination of its part number and
c. Trip Cycle: A trip cycle is defined as a
serial number. Parameters to be tracked are
cycle from zero gas generator speed
shown in the Critical Parts Tracking System
with acceleration to high power
Data Sheet shown in figure 13-2. A data sheet
setting (any power setting above
must be created and maintained for each
synchronous idle), followed by rapid
critical part throughout its entire life.
(uncontrolled) shutdown. An example
would be a fuel metering valve being CAUTION It is the owner’s/user’s
immediately closed. A decel-to- responsibility to establish a tracking system
minimum load or step-to-idle are not to ensure that adequate records are
considered trip cycles for the purpose maintained for each critical life-limited part
of Critical Parts Life Management. and that no such part exceeds its life limit.
d. Declared Life: Declared life is the When any critical life-limited part is
cyclic life limit of a critical life-
limited part. transferred from one location to another or
used as a rotable spare, this event must be
e. Accumulated Cycles: Accumulated recorded on the Critical Parts Tracking System
cycles represent the calculated life Data Sheet for that part. The data sheet,
consumed by a part, considering both containing the life history record of a critical
full, partial, and trip cycles life-limited part, maintains documentation of
experienced by the part during
operation. the parts cyclic life history as the part transfers
from one location to another.
f. Full Cycle Factor: Coefficient used as
a numeric expression of the amount of
damage caused by a full cycle (Kf).
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13-5 Calculating Accumulated a. Accumulated Cycles = (Kf x Full
Cycles and Recording Data Cycles) + (Kp x Partial Cycles) + (Kt x
Trip Cycles)
As defined in paragraph 13-2, a cycle may be
designated as full, partial, or trip. In order to b. The coefficients Kf, Kp, and Kt
take credit for the increased capability of a are listed for each component in
partial cycle, the life consumed is calculated table 13-1.
by considering full, partial, and trip cycles.
The owner/user is responsible for the mainte-
The consumed life of the part is designated as
nance of accurate records of all engine hours
the accumulated cycles of the part.
and cycles. The operator should monitor status
Accumulated cycles are calculated using the
of the parts to ensure that none listed in
equation:
table 13-1 exceed the declared life limits pub-
lished in this chapter.
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Table 13-1 Declared Life Limits for LM6000 PC Engine
Industrial Life
Module Component Part Number Kf Kp Kt
Limit (Cycles)
LPCR
Stg 0 Disk L24546P05 20,000 1 See Note 1 1
Stg 1 Disk L24547P03 20,000 1 1
Stg 2-4 Spool 1781M30G04 20,000 1 1
LPC Fwd Shaft L24548P06 20,000 1 1
LPC Fwd Shaft L44648G01, G02 TBD TBD TBD
FMS
Fwd Shaft 9080M27P09 8,500 1 1
Mid Shaft L47747P01, P02, P03 TBD TBD TBD
HPCR
Stg 1 Disk 9380M26P06 10,000 1 1.97
Stg 2 Disk 9380M27P08 10,000 1 1.96
Stg 2 Disk 9380M27P10 10,000 1 TBD
Stg 3-9 Spool 1333M66G10 10,000 1 1.76
1333M66G09, G13, G14,
Stg 3-9 Spool 10,000 1 TBD
and L44863G03
Stg 3-9 Spool L44659P01 TBD TBD TBD
1703M49G01, G02,
Stg 10-14 Spool 10,000 1 TBD
G03, G04
CDP Seal L47299P02 10,000 1 3.94
L47299P03,
CDP Seal 1782M82P02, P03, and 10,000 1 TBD
L43372P04
HPTR
Stg 1 Disk 1531M84G10, G12 10,100 1 1.688
Stg 1 Disk 1531M84G11 TBD TBD TBD
Stg 2 Disk 9362M43P05 6,200 1 2.67
Stg 2 Disk 9362M43P10 10,000 1 TBD
Spacer 1539M12P01, P02 15,900 1 1.823
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Table 13-1 Declared Life Limits for LM6000 PC Engine (Continued)
Industrial Life
Module Component Part Number Kf Kp Kt
Limit (Cycles)
LPTR See Note 1
Stg 1 Disk L47741P01 10,000 1 TBD
Stg 1 Disk L47741P02 10,000 1 TBD
Stg 2 Disk L47742P01 10,000 1 TBD
Stg 2 Disk L47742P02 10,000 1 TBD
Stg 3 Disk L47743P02, P04 10,000 1 TBD
Stg 4 Disk L47744P02, P03, P05 10,000 1 TBD
Stg 5 Disk L47745P02, P03 10,000 1 TBD
Shaft L47746P01 10,000 1 TBD
L45001P07 and
Balance Piston 10,000 1 TBD
L47958P01, P02
Note 1: For appropriate partial cycle factor (Kp), refer to Partial Cycle definition in paragraph 13-2.b.
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Figure 13-2 Critical Parts Tracking System Data Sheet Example
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APPENDIX A
Fuel/Water Requirements
This appendix contains specifications for the following:
A1 Fuel Gases
A2 Liquid Fuel
A3 Water Purity - NOx Suppression
A4 Water Purity - Compressor Cleaning
A5 Liquid Detergent - Compressor Cleaning
A6 Lubricating Oil
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Appendix A1
Fuel Gases for Combustion in AeroDerivative Gas Turbines
A1-1 General Table A1-2 identifies the fuel composition
limits for aeroderivative gas turbines with Dry
GE AeroDerivative gas turbines have the abil- Low Emission (DLE) combustion systems and
ity to burn a wide range of gaseous fuels as Table A1-3 identifies the fuel composition
shown in Table A1-1. These gases present a limits for aeroderivative gas turbines with
broad spectrum of properties due to both Standard (Single Annular Combustor - SAC)
active and inert components. This specifica- combustion systems.
tion is designed to define guide-lines that must
be followed in order to burn these fuels in an
efficient, trouble-free manner, while protect-
ing the gas turbine and supporting hardware.
Table A1-1 Fuel Classification
LHV
Fuel Btu/scf Major Components
Pipeline Natural Gas and Liquefied 800 - 1200 Methane
Natural Gas
Liquefied Petroleum Gas 2300 - 3200 Propane Butane
Gasification Gases
- Air Blown 100 - 150 Carbon Monoxide, Hydrogen, Nitrogen,
Water Vapor
- Oxygen Blown 200 - 400 Carbon Monoxide, Hydrogen, Water Vapor
Process Gases 300 - 3000 Methane, Hydrogen, Carbon Monoxide,
Ethane, Ethene, Propane, Propene, Carbon
Dioxide, Nitrogen
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Table A1-2 Fuel Gas Composition Limits for DLE Configuration
Parameter Requirements - DLE Configuration
Minimum Maximum
Modified Wobbe Index (See Note 1) 40 (See Note 2) 60
Methane (CH4) 50% Vol 100% vol
Ethane (C2+ paraffins)
LM1600 0 35% Vol
LM2500 / LM2000 0 35% Vol
LM2500+G4 0 30% Vol
LM6000 / LMS100 0 24% Vol
Hydrogen (H2) 0 5% Vol (See Note 2)
Diolefins (i.e. Butadiene, Propadiene) 0 None allowed
Other combustibles (See Note 3) 0 Consult GE
Notes:
1. MWI at max limits C2+.
2. Other levels may be possible. Consult GE.
3. Other combustibles - CO, olefin hydrocarbons, etc.
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Table A1-3 Fuel Gas Composition Limits for SAC Configuration
Parameter Requirements - SAC Configuration
Minimum Maximum
Modified Wobbe Index (See Note 1)
LMS100 Low MWI Nozzles 35 44
LMS100 Standard MWI Nozzles 45 60
All Other LM 40 60
Hydrogen + 1/2 CO (H2 + 1/2 CO)
(See Note 2)
LM2500 / LM2000 0 85% Vol
LM2500+ / +G4 / LM1600 / LM5000 0 75% Vol
LM6000 / LMS100 0 35% Vol
Diolefins (i.e. Butadiene, Propadiene) 0 See Note 3
Olefins 0 15% Vol (See Note 4)
Other combustibles (See Note 5) 0 Consult GE
Notes:
1. Expanded values may be possible with fuel nozzle modifications. Consult GE.
2. High hydrogen and carbon monoxide content fuels have large rich to lean flammability limits.
These types of fuels often require inert gas purging of the gas turbine gas fuel system upon unit
shutdown or a transfer to a more conventional fuel. When process gas fuels have extreme flam-
mability limits such that the fuel will auto ignite at turbine exhaust conditions, a more “conven-
tional” start-up fuel, such as methane, is required.
3. The presence of even trace amounts of butadiene in the gas fuel may cause fuel system fouling.
Additional fuel system maintenance may be required when using fuels containing butadiene.
4. Olefins in the gas fuel at moderate levels (<15%) are not expected to present problems as long as
the fuel temperature is kept below 176°F (80°C). With a higher levels of olefins or with a higher
gas fuel temperature, fuel system fouling may be an issue.
5. Other combustibles - CO, hydrocarbons. etc.
NOTE • Values and limits apply at the inlet of the
For Tables A1-1, A1-2, and A1-3: gas fuel control module.
• Heating value ranges shown are provided
• When considering the use of alternate
as guidelines. Specific fuel analysis must
fuels, provide details of the fuel constitu-
be furnished to GE for evaluation. The
ents, fuel pressure, fuel temperature, and
standard configured single annular com-
expected engine usage conditions and
bustor (SAC) gas turbines require a fuel
operating characteristics to GE for evalua-
with a Low Heating Value (LHV) no less
tion and recommendations.
than of 6500 Btu/pound. The Dry Low
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Emissions (DLE) combustion system • Modified Wobbe Number Index (MWI), is
requires a minimum LHV of 18,000 Btu/ described in paragraph A1-3.2.
pound. (Reference paragraph A1-3.1).
Table A1-4 Identifies the acceptable test meth-
• The fuel gas supply shall be 100% free of ods to be used in determining gas fuel proper-
liquids. Admission of liquids can result in ties.
combustion and/or hot gas path compo-
nent damage. (Reference paragraph
A1-3.3).
Table A1-4 Test Methods for Gaseous Fuels
PROPERTY ACCEPTABLE METHODS
Gas Composition ASTM D1945 - Standard method for constituents of
gases by Gas Chromatography, or
ISO 6974 - Natural Gas -- Determination of composi-
tion from C1 to C8 with defined uncertainty by
Gas Chromatography
ISO 6975 - Natural Gas -- Determination of Hydrocar-
bons from Butane (C4) to Hexadecane (C16) --
Gas Chromatographic Method
Heating Value ASTM D3588 - Procedure for Calculating Calorific
Value and Specific Gravity of Gaseous Fuels,
Specific Gravity or
Compressibility Factor ISO 6976 - Natural gas -- Calculation of Calorific Val-
ues, Density, Relative Density and Wobbe
Index from composition
GPA 2172 - Calculation of Gross Heating Value, Rela-
tive Density and Compressibility Factor for Nat-
ural Gas Mixtures from Compositional Analysis
Dew Point (See Note 1) ASTM D1142 - Water vapor content of Gaseous Fuels
by measurement of Dew Point Temperature
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Table A1-4 Test Methods for Gaseous Fuels (Continued)
PROPERTY ACCEPTABLE METHODS
Sulfur ASTM D1072 - Total sulfur in Fuel Gases by Combus-
tion and Barium Chloride Titration, or
ASTM D3246 - Sulfur in Petroleum Gas by Oxidative
Microcoulometry (See Note 2)
ASTM D5504 - Sulfur Compounds in Natural Gas and
Gaseous Fuels by Gas Chromatography and
Chemiluminescence
ASTM D6667 - Determination of Total Volatile Sulfur in
Gaseous Hydrocarbons and Liquefied Petro-
leum Gases by Ultraviolet Fluorescence
ASTM D6968 - Simultaneous Measurement of Sulfur
Compounds and Minor Hydrocarbons in Natu-
ral Gas and Gaseous Fuels by Gas Chroma-
tography and Atomic Emission Detection
ISO 4260 - Petroleum Products and Hydrocarbons -
Determination of Sulfur Content - Wickbold
Combustion Method
ISO 6326 - Natural Gas -- Determination of Sulfur
Compounds
ISO 19739 - Natural Gas -- Determination of Sulfur
Compounds using Gas Chromatography
IP 243 - Petroleum Products and Hydrocarbons -
Determination of Sulfur Content - Wickbold
Combustion Method
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Table A1-4 Test Methods for Gaseous Fuels (Continued)
PROPERTY ACCEPTABLE METHODS
Chemical Composition ASTM D2650 - Chemical Composition of Gases by
Mass Spectrography
ASTM - ASTM International
ISO - International Organization for Standardization
GPA - Gas Processors Association
IP - Institute of Petroleum UK
Notes:
1. Hydrocarbon and water dew points shall be determined by direct dew point measurement (Chilled
Mirror Device). If dew point cannot be measured, an extended gas analysis, which identifies hydro-
carbon components from C1 through C14, shall be performed. This analysis must be accurate within
10 ppmv. A standard gas analysis to C6+ is normally not acceptable for dew point calculation unless it
is known that heavier hydrocarbons are not present, as is most often the case with liquefied natural
gases.
2. This test method will not detect the presence of condensable sulfur vapor. Specialized filtration equip-
ment is required to measure sulfur at concentrations present in vapor form. Contact GE for more
information.
A1-2.1.1 Pipeline Natural Gas
A1-2 Fuel Gas Classification
Natural gases normally fall within the calorific
A1-2.1 Natural Gas, Liquefied Natural heating value range of 800 to 1200 Btu/scf
Gas (LNG), Medium BTU (LHV). Actual calorific heating values are
Natural Gas, and Liquefied dependent on the percentages of hydrocarbons
Petroleum Gas (LPG) and inert gases contained in the gas. Natural
gases are found in and extracted from under-
Natural gases are predominantly methane with ground reservoirs. These "raw gases" may
much smaller quantities of the slightly heavier contain varying degrees of nitrogen, carbon
hydrocarbons such as ethane, propane, and dioxide, hydrogen sulfide, and contain con-
butane. Liquefied petroleum gas is propane taminants such as salt water, sand, and dirt.
and/or butane with traces of heavier Processing by the gas supplier normally
hydrocarbons. reduces and/or removes these constituents and
contaminants prior to distribution. A gas
analysis must be performed to ensure that the
fuel supply to the gas turbine meets the
requirements of this specification.
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A1-2.1.2 Liquefied Natural Gas A1-2.2 Gasification Fuels
Liquefied Natural Gas (LNG) is produced by Other gases that may be utilized as gas turbine
drying, compressing, cooling and expanding fuel are those formed by the gasification of
natural gas to approximately -260°F at coal, petroleum coke, or heavy liquids. In gen-
14.7 psia (-162°C at 101.4 kPa). The product eral, the heating values of gasification fuels
is transported as a liquid and delivered as a gas are substantially lower than other fuel gases.
after pressurizing and heating to ambient tem- These lower heating value fuels require that
perature. The composition is free of inerts and the fuel nozzle gas flow passages be larger
moisture and can be treated as a high quality than those utilized for fuels of higher heating
natural gas. LNG can pick up moisture that is values.
present in the pipeline but it is not a source of
the moisture. Gasification fuels are produced by either an
Oxygen Blown or Air Blown gasification pro-
A1-2.1.3 Medium BTU Natural Gas cess.
Natural gases are found in and extracted from A1-2.2.1 Oxygen Blown Gasification
underground reservoirs. These "raw gases"
may contain varying degrees of nitrogen, car- The heating values of gases produced by Oxy-
bon dioxide, hydrogen sulfide, and contain gen Blown Gasification fall in the range of
contaminants such as salt water, sand, and dirt. 200 to 400 Btu/scf (7856-15752 kJ/NM3). The
The heating values of Medium BTU Natural Hydrogen (H2) content of these fuels is nor-
Gas normally fall between 400 and 800 mally above 30 percent by volume and have
Btu/scf (LHV). Processing by the gas supplier H2/CO mole ratio between 0.5 to 0.8. Oxygen
normally reduces and/or removes these con- Blown Gasification fuels are often mixed with
stituents and contaminants prior to use in the steam for thermal NOx control, cycle effi-
gas turbine. A gas analysis must be performed ciency improvement, and/or power augmenta-
to ensure that the fuel supply to the gas turbine tion. When utilized, the steam is injected into
meets the requirements of this specification. the combustor by an independent passage.
Due to high hydrogen content of these fuels,
Oxygen Blown Gasification fuels are nor-
A1-2.1.4 Liquefied Petroleum Gases mally not suitable for DLE applications.
The heating values of Liquefied Petroleum A1-2.2.2 Air Blown Gasification
Gases (LPGs) normally fall between 2300 and
3200 Btu/scf (LHV). Based on their high com- Gases produced by Air Blown Gasification
mercial value, these fuels are normally utilized normally have heating values between 150
as a back-up fuel to the primary gas fuel for and 200 Btu/scf (5907-7876 kJ/NM3) LHV.
gas turbines. Since LPGs are normally stored The H2 content of these fuels can range from 8
in a liquid state, it is critical that the vaporiza- to 20 percent by volume and have a H2/CO
tion process and gas supply system maintains mole ratio of 0.3 to 3:1. The use and treatment
the fuel at a temperature above the minimum of these fuels are similar to that identified for
required superheat value. Fuel heating and Oxygen Blown Gasification.
heat tracing are required to ensure this.
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For gasification fuels, a significant part of the A1-2.3.2 Coke Oven Gases
total turbine flow comes from the fuel. In
addition, for oxygen blown fuels, there is a Coke Oven Gases are high in H2 and CH4 and
diluent addition for NOx control. Careful inte- may be used as fuel for SAC systems, but are
gration of the gas turbine with the gasification not suitable for DLE combustion applications.
plant is required to assure an operable system. These fuels often contain trace amounts of
Due to the low volumetric heating value of heavy hydrocarbons which, when burned,
both oxygen and air blown gases, special fuel could lead to carbon buildup on the fuel noz-
systems and fuel nozzles are required. zles. The heavy hydrocarbons must be
"scrubbed" or removed from the fuel prior to
A1-2.3 Process Gases delivery to the gas turbine or maintained in the
gaseous state.
Many chemical processes generate surplus
gases that may be utilized as fuel for gas tur- A1-2.3.3 Flare Gases
bines, for example, tail or refinery gases.
These gases often consist of methane, hydro- Flare Gases are produced by a number of asso-
gen, carbon monoxide, and carbon dioxide ciated gas activities including oil wells or oil
that are normally by-products of petrochemi- rigs, refineries, chemical plants, and landfills.
cal processes. Due to the hydrogen and car- Associated gases from oil production and
bon monoxide content, these fuels have large refineries are normally flared, but can also be
rich-to-lean flammability limits. These types a good fuel source for power production.
of fuels often require inert gas purging of the These associated gases can be high in methane
gas turbine gas fuel system upon unit shut- and C2+ gases and must be evaluated on a
down or a transfer to a more conventional fuel. case by case basis by GE. Refinery gases are
When process gas fuels have extreme flamma- also known to contain butadienes which must
bility limits such that the fuel will auto ignite be removed prior to use. Gases produced from
at turbine exhaust conditions, a more “conven- chemical plants are usually the result of a
tional” start-up fuel, such as methane, is chemical reaction and will vary in heating
required. value depending on the composition and pro-
cess. In landfills, gas which results from
Additional process gases utilized as gas tur- the decomposition of materials buried in
bine fuels are those that are by-products of the landfill can be a source fuel for power
steel production. These are: production. These types of gases are usually
in the low to medium heating value range
A1-2.3.1 Blast Furnace Gases (BFGs) (300-450 Btu/scf) and normally contain silox-
anes.
Blast Furnace Gases (BFGs), alone, have heat-
ing values below minimal allowable limits.
These gases must be blended with other fuel to
raise the heating value to above the required
limit. Coke Oven and/or Natural Gases or
hydrocarbons such as propane or butane can
be utilized to accomplish this.
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A1-3 Fuel Properties Tiratsoo, Scientific Press, Ltd., Beaconsfield,
England, 1972). This term is a measurement
A1-3.1 Heating Value of volumetric energy and is calculated using
the LHV of the fuel, specific gravity of the
A fuel's heat of combustion, or heating value, fuel with respect to air at International Stan-
is the amount of energy, expressed in British dards Organization (ISO) conditions, and the
Thermal Unit (BTU), generated by the com- fuel temperature, as delivered to the gas tur-
plete combustion, or oxidation, of a unit bine.
weight of fuel. The amount of heat generated
by complete combustion is a constant for a The mathematical definition is as follows:
given combination of combustible elements
and compounds. Modified Wobbe Index
For most gaseous fuels, the heating value is =LHV/(SGgas x Tgas)1/2
determined by using a constant pressure, con-
tinuous-type calorimeter. This is the industry This is equivalent to:
standard. In these units, combustible sub-
stances are burned with oxygen under essen- Modified Wobbe Index
tially constant pressure conditions. In all fuels
=LHV/([MWgas/28.96] x Tgas)1/2
that contain hydrogen, water vapor is a prod-
uct of combustion, which impacts the heating Where:
value. In a bomb calorimeter, the products of
combustion are cooled to the initial tempera- LHV = Lower Heating Value of the Gas
ture and all of the water vapor formed during Fuel (Btu/scf)
combustion is condensed. The result is the
HHV, or higher heating value, which includes SGgas = Specific Gravity of the Gas Fuel
the heat of vaporization of water. The LHV, Relative to Air
assumes all products of combustion, including
water remain in the gaseous state, and the MWgas = Molecular Weight of the Gas Fuel
water heat of vaporization is not available. It is
a common practice in the gas turbine industry Tgas = Absolute Temperature of the Gas
to utilize the LHV when calculating the over- Fuel (Rankine)
all cycle thermal efficiency.
28.96 = Molecular Weight of Dry Air
A1-3.2 Modified Wobbe Index Range
The allowable Modified Wobbe Index range
While gas turbines can operate with gases between 40 and 60 is established to ensure that
having a very wide range of heating values, required fuel nozzle pressure ratios be main-
the amount of variation that a single specific tained during all combustion/turbine modes of
fuel system can accommodate is much less. operation for standard fuel system configura-
Variation in heating value as it affects gas tur- tions. An accurate analysis of all gas fuels,
bine operation is expressed in a term identified along with fuel gas temperature profiles shall
as Modified Wobbe Index (Natural Gas, E. N. be submitted to GE for proper evaluation.
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A1-3.3 Superheat Requirement A1-4 Contaminants
The superheat requirement is established to Dependent on the type of fuel gas, the geo-
ensure that the fuel gas supplied to the gas tur- graphical location, and the forwarding means,
bine is 100 percent free of liquids. Dependent there is the potential for the "raw" gas supply
on its constituents, gas entrained liquids could to contain one or more of the following con-
cause degradation of gas fuel nozzles and, for taminants:
DLE applications, premixed flame flashbacks
or re-ignitions. 1. Tar, lamp black, coke
A minimum of 50°F (28°C) of superheat is 2. Water, salt water
required and is specified to provide enough
margin to compensate for temperature reduc- 3. Sand, clay
tion due to pressure drop across the gas fuel
control valves. A minimum of 20°F (11°C) of 4. Rust
superheat is required at the gas turbine fuel
5. Iron sulfide
manifold inlet connection.
6. Scrubber oil or liquid
A1-3.4 Gas Constituent Limits
7. Compressor lube oil
Gas constituents are not specifically limited
except to the extent described above. These 8. Naphthalene
limitations are set forth to assure stable com-
bustion through all gas turbine loads and 9. Gas hydrates
modes of operation. Limitations are more
stringent for DLE combustion systems where 10. Siloxanes
“premixed” combustion is utilized. A detailed
gas analysis shall be furnished to GE for It is critical that the fuel gas is properly condi-
proper evaluation. tioned prior to being utilized as gas turbine
fuel. This conditioning can be performed
A1-3.5 Gas Fuel Supply Pressure using a variety of methods. These include, but
are not limited to, media filtration, inertial
Gas fuel supply pressure requirements are separation, coalescing, and fuel heating.
dependent on the gas turbine model and com- Trace metal, particulate, and liquid contamina-
bustion design, the fuel gas analysis, and unit tion limits are provided in the following para-
specific site conditions. Minimum and maxi- graphs. These limits are given in parts per
mum supply pressure requirements can be million by weight (ppmw) corrected to the
determined by GE for specific applications. actual heating value of the fuel. It is critical
that fuel gas conditioning equipment be
designed and sized so that these limits are not
exceeded.
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A1-4.1 Particulates A1-4.3 Sulfur
Contamination limits for particulates are Sulfur can sometimes be found in natural gas
established to prevent fouling and excessive in the compounds “H2S” and/or “COS”. It is
erosion of hot gas path parts, erosion and plug- produced with the natural gas. Typically the
ging of combustion fuel nozzles and erosion gas supplier will limit H2S to a concentration
of the gas fuel system control valves. The uti- of less than approximately 20 ppmv by remov-
lization of gas filtration or inertial separation ing sulfur in a treatment system. Sulfur may
is required. The filtration level should be a also be present in very low concentrations
beta ratio of 200 minimum (efficiency of (<100 ppbv) in the form of elemental sulfur
99.5%) at 5μ or less. The total particulate vapor.
should not exceed 30 ppm by weight. GE
requires the use of stainless steel piping down- There is no specific limit on natural gas fuel
stream of this last level of filtration. sulfur content if the engine is used in an appli-
cation where both the fuel and environment
A1-4.2 Liquids are free of alkali metals, including sulfur com-
pounds. There are several concerns relative to
No liquids are allowed in the gas turbine fuel the levels of sulfur contained in the fuel gas
gas supply. Liquids contained in the fuel can supply. Many of these are not directly related
result in nuisance and/or hardware damaging to the gas turbine but to associated equipment
conditions. These include rapid excursions in and emissions requirements.
firing temperature and gas turbine load, pri-
mary zone re-ignition and flashback of pre- These concerns include but are not limited to:
mixed flames, and when liquids carry over
past the combustion system, melting of hot gas A1-4.3.1 Hot Gas Path Corrosion
path components. When liquids are identified
in the gas supply, separation and heating is Typically, use of sulfur bearing fuels will not
employed to achieve the required superheat be limited by concerns for corrosion in the tur-
level. bine hot gas path unless alkali metals are pres-
ent. Sodium, potassium and other alkali metals
Gas at the wellhead is typically produced in a are not normally found in natural gas fuel, but
wet saturated condition and is treated to are typically found to be introduced in the
remove water and heavy hydrocarbon liquids. compressor inlet air in marine environments,
Depending on the degree of treatment and the as well as in certain adverse industrial envi-
supply pressure, the gas may be delivered in a ronments. The total amount of sulfur and
dry condition. After pressure reduction it is alkali metals from all sources shall be limited
possible for condensates to form as the gas to form the equivalent of 0.6 ppm of alkali
cools during expansion. The condensates may metal sulfates in the fuel. Unless sulfur levels
be either water or hydrocarbons or both. Carry are extremely low, alkali levels are usually
over of lubricating oil from compressor sta- limiting in determining hot corrosion of hot
tions is another source liquids. gas path materials.
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For low BTU gases, the fuel contribution of A1-4.3.2 HRSG Corrosion
alkali metals at the turbine inlet is increased
over that for natural gas and the alkali limit in If heat recovery equipment is used, the con-
the fuel is therefore decreased. The total centration of sulfur in the fuel gas must be
amount of alkali metals(a) in gas fuels used known so that the appropriate design for the
with engines having marinized (corrosion- equipment can be specified. Severe corrosion
resistant) coatings on the high pressure turbine from condensed sulfuric acid results if a Heat
blading shall not exceed 0.2 ppm(b). Recovery Steam Generator (HRSG) has metal
temperatures below the sulfuric acid dew
(a) Sodium, potassium, and lithium. point. Contact the HRSG supplier for addi-
Experience has shown that tional information.
sodium is by far the preponderant
alkali metal, if any, found in gas- A1-4.3.3 Selective Catalytic Reduction
eous fuels. (SCR) Deposition
(b) Units utilizing ammonia injection downstream
This limit assumes zero alkali
metals in the inlet air or injected of the gas turbine for NOx control can experi-
water or steam. When actual lev- ence the formation of deposits containing
els are above zero, the maximum ammonium sulfate and bisulfate on low tem-
allowable sodium content of the perature evaporator and economizer tubes.
fuel must be reduced in accor- Such deposits are quite acidic and therefore
dance with the following corrosive. These deposits, and the corrosion
relationship: that they cause, may also decrease HRSG per-
formance and increase back pressure on the
gas turbine. Deposition rates of ammonium
ppm sodium inlet air × sulfate and bisulfate are determined by the sul-
Air/Fuel ratio = fur content of the fuel, ammonia content in the
exhaust gas, tube temperature, and boiler
ppm sodium in water or
design. Fuels having sulfur levels above those
steam × water or steam ratio
used as odorants for natural gas should be
Fuel =
reported to GE. In addition, the presence of
ppm sodium in fuel = minute quantities of chlorides in the inlet air
Total fuel equivalence for may result in cracking of AISI 300 series
sodium from all sources not ______ stainless steels in the hot gas path. Contact the
to exceed 0.2 ppm SCR supplier for additional information.
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A1-4.3.4 Exhaust Emissions sition take place, fuel heating will be required
to maintain the sulfur in vapor phase and
Sulfur burns mostly to sulfur dioxide, but 5 avoid deposition. A gas temperature of 130°F
percent to 10 percent oxidizes to sulfur triox- (54°C) or higher may be required at the inlet
ide. The latter can result in sulfate formation, to the gas control valves to avoid deposition,
and may be counted as particulate matter in depending on the sulfur vapor concentration.
some jurisdictions. The remainder will be dis- The sulfur vapor concentration can be mea-
charged as sulfur dioxide. To limit the dis- sured by specialized filtering equipment. If
charge of acid gas, some localities may restrict required, GE can provide further information
the allowable concentration of sulfur in the on this subject.
fuel.
A1-4.4 Siloxanes
A1-4.3.5 Elemental Sulfur Deposition
Siloxanes are sometimes found in non-tradi-
Solid elemental sulfur deposits can occur in tional gas fuels such as those obtained from
gas fuel systems downstream of pressure landfills. Siloxanes should be removed with
reducing stations or gas control valves under current technology so that the content is as
certain conditions. Power reduction has been low as possible, but not to exceed 50 ppb by
observed for DLE applications due to elemen- weight in the fuel gas. If the application
tal sulfur. These conditions may be present if includes wet NOx controls, the silica limit for
the gas fuel contains elemental sulfur vapor, the water or steam is reduced to 50 ppb by
even when the concentration of the vapor is a weight. Gas sampling and analysis is required
few parts per billion by weight. Concentra- and should include either an impinger or sor-
tions of this magnitude cannot be measured by bent collection method and have a laboratory
commercially available instrumentation, and with Gas Chromatography coupled with Mass
deposition cannot therefore be anticipated Spectrometer (GC-MS) capability to analyze
based on a standard gas analysis. Should depo- the samples collected.
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A1-5 Definitions ing 50°F (28°C) of superheat above the mois-
ture dew point will eliminate hydrate
A1-5.1 Dew Point formation problems.
This is the temperature at which the first liquid A1-5.5 Glycol
droplet will form as the gas temperature is
reduced. Common liquids found in gas fuel Glycol is not a natural constituent of natural
are hydrocarbons, water, and glycol. Each one gas, but is introduced during the dehydration
has a separate and measurable dew point. The process. Various forms of glycol are used,
dew point varies considerably with pressure, diethylene and triethylene glycol being two
and both temperature and pressure must be most common. In some cases, glycol is
stated to properly define the gas property. Typ- injected into the pipeline as a preservative. In
ically, the hydrocarbon dew point will peak in most cases, glycol may only be a problem dur-
the 300 to 600 psia (2068 to 4137 kPa) range. ing commissioning of a new pipeline or if an
upset has taken place at an upstream dehydra-
A1-5.2 Dry Saturated Condition tion station.
The gas temperature is at, but not below or A1-5.6 Odorant
above, the dew point temperature. No free liq-
Odorants are injected into natural and LP gas
uids are present.
to make leaks readily detectable. The odorant
A1-5.3 Gas Hydrates commonly used for natural gas is tertiary butyl
mercaptan, while ethyl mercaptan is used for
Gas hydrates are semi-solid materials that can LP gas.
cause deposits that plug instrumentation lines,
control valves, and filters. They are formed A1-5.7 Superheat
when free water combines with one or more of This is defined as the difference between the
the C1 through C4 hydrocarbons. Typically, gas temperature minus the liquid dew point.
the formation will take place downstream of a The difference is always positive or zero. A
pressure reducing station where the tempera- negative value implies that the value is being
ture drop is sufficient to cause moisture con- measured at two different states of pressure
densation in a region of high turbulence. and temperature and is not valid. A measured
Because hydrates can cause major problems in gas temperature below the theoretical dew
the gas distribution network, the moisture con- point means that the gas is in a wet saturated
tent is usually controlled upstream at a dehy- state with free liquids present.
dration process station.
A1-5.8 Saturation Line
A1-5.4 Gas Hydrate Formation Line
This is the same as the dew point line.
This is similar to the dew point line except the
temperature variation with pressure is much A1-5.9 Wet Saturated Condition
less. The hydrate line is always below or at the
moisture dew point line as free water must A point where a mixture consists of both
exist in order for hydrates to form. Maintain- vapor and liquids.
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Appendix A2
Liquid Fuel Requirements for GE AeroDerivative Gas Turbines
This document lists specifications and ASTM D1655 - Standard Specification for
describes application guidelines for liquid Aviation Turbine Fuels (Jet-A and Jet-A1)
fuels that can be fired satisfactorily in GE
AeroDerivative gas turbines. It is recom- ASTM D6615 - Standard Specification for
mended that a complete specification analysis Jet-B1 Wide-Cut Aviation Fuels
of all liquid fuels proposed for use in GE ASTM D7566 - Standard Specification for
AeroDerivative gas turbines be reviewed by Aviation Turbine Fuels Containing Synthetic
GE prior to use. Hydrocarbons
A2-1 Fuel Specifications MIL-DTL-16884 - Detail Specification,
Naval Distillate (NATO F-76)
Fuels conforming to the following military
and industry specifications are acceptable for VV-F-800 - Federal Specification, Fuel Oil -
use in GE gas turbines in industrial and ship- Diesel, Grades DF-A, DF-1, and DF-2
board applications, except as noted below, and (NATO F-54)
provided they also meet the additional criteria
described in paragraph A2-2. However, their ASTM D396 - Standard Specification for
use should be reviewed against applicable Fuel Oils, Grades No. 1, 2, 4, and 4 (Light)
safety and regulatory requirements. ASTM D2880 - Standard Specification for
Gas Turbine Fuel Oils, Grades No. 0-GT1, 2,
D50TF2 - Specification Aviation Turbine Fuel
No. 1-GT, No. 2-GT
(GEAE)
ASTM D6751 - Standard Specification for
ISO 8217 - Petroleum Products-Fuel (Class F) -
Biodiesel Fuel Blend Stock (B100) for Middle
Specification of Marine Fuels (MGO)
Distillate Fuels
MIL-DTL-5624 - Turbine Fuels, Aviation,
Other:
Grades JP-41, and JP-5/JP-8 ST (NATO F-40,
44) The pure hydrocarbon combustibles2 [e.g.,
butane (C4H10) and pentane (C5H12), both
MIL-DTL-83133 - Turbine Fuel, Aviation,
normal and iso] are acceptable either alone or
Kerosene Type, JP-8 (NATO F34/F35), and
in various mixtures with other liquid fuels,
JP-8+100 (NATO F37)
providing that fuel manifold pressures are suf-
ASTM D975 - Standard Specification for ficient to maintain the fuel in the liquid state.
Diesel Fuel Oil, Grades 1-D, 2-D, 1-D Low Alternate fuels may be required for starting
Sulfur, and 2-D Low Sulfur and low-power operation. Contact GE for spe-
cific applications.
1 2
Highly volatile wide-cut fuels (such as MIL-DTL-5624 Liquefied gas fuels, light distillates, and alcohols may
JP-4, ASTM D6615 Jet-B, and ASTM D2880 Grade have inadequate lubricity, requiring the use of a fuel
No. 0-GT) are generally acceptable for industrial, but not pump/system specifically designed to handle these types
shipboard applications. of fuels. See paragraph A2-2.2.
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Light distillate fuels2, such as Naphtha (C10 A2-2.1 Composition
down to C4 hydrocarbons), gasoline (C7 to C5
hydrocarbons), and D2880 Grade No. 0-GT, The fuel shall consist of hydrocarbon com-
are acceptable as fuels in GE AeroDerivative pounds, except where oxygenates are either
gas turbines provided fuel manifold pressures permitted as part of the specification, such as
are sufficient to maintain fuel as a liquid, espe- biodiesel, or agreed to with the user, such as
cially in hot climates. Alternative fuels may be methanol. The fuel composition must be com-
necessary for starting the engines and low- patible between brands and batches.
power operation. Contact GE for specific
applications. While there is no specific requirement or limit
on the amount of fuel-bound nitrogen (FBN)
Various alcohols2 [e.g., hydroxyl derivatives contained in a liquid fuel, it is recommended
of hydrocarbons, such as methanol (CH3OH) that the amount of liquid fuel FBN be under-
and ethanol (C2H5OH)] can burn in GE Aero- stood for those applications that are sensitive
Derivative gas turbines. Contact GE for spe- to levels of oxides of nitrogen (NOx) in the
cific applications. gas turbine exhaust. FBN is the amount of
nitrogen in the fuel that is chemically bound.
Fuels conforming to ASTM D975 and D396 During the combustion process, the FBN is
may contain blends of up to 5% biodiesel per converted, at least partially, to NOx (called
the respective specifications. Biodiesel blends organic NOx) and adds to the total amount of
greater than 5% must be reviewed by GE. Any NOx that is contained in the gas turbine
biodiesel in blends must conform to ASTM exhaust. GE emissions data provided for liq-
D6751 and the blend must meet the require- uid fuels assumes an FBN content of less than
ments of this specification. Biodiesel blends 0.015 percent by weight unless otherwise
have additional requirements described in noted.
paragraph A2-4.1.
A2-2.2 Viscosity
A2-2 Property Requirements
The viscosity of the fuel as supplied to the
The following requirements supplement and inlet connection on the gas turbine, shall be a
supersede, where there is a conflict, the speci- minimum of 0.5 centistoke3, and shall be up to
fications listed in paragraph A2-1. However, if 6.0 centistokes maximum for starting and 12.0
the specification is more restrictive, it applies. centistokes maximum during operation. The
fuel may be heated to meet this requirement.
Property requirements are listed in
Table A2-1. Contaminant limits apply to fuel
samples taken at the gas turbine fuel manifold
flange. It cannot be assumed that specification
fuel supplied by a refinery still meets those
specifications once it is delivered to the gas
turbine.
3 Required for adequate GE AeroDerivative gas turbine
fuel pump lubrication and to prevent pump cavitation
when using light fuels.
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A2-2.3 Wax (b) The temperature required to
remain within maximum fuel vis-
Wax can be present in fuel oil, specially the cosity requirements, or 35°F
distillates with higher pour points. It may be (2°C).
necessary to determine the percent of wax and
its melting point and to provide a suitable The maximum temperature of liquid fuel sup-
method to keep the wax dissolved at all times. plied to the gas turbine should not exceed
150°F (65.6°C). For liquid fuels with high
A2-2.4 Additives vapor pressure constituents (naphtha, NGL,
etc.), the fuel temperature in the manifold
The use of any dyes or additives requires should be at least 100°F (55.6°C) below the
approval of GE, unless such additives are spe- bubble point temperature of the lightest com-
cifically approved in the fuel specifications ponent at high pressure compressor discharge
(1.0) or, they conform to MIL-S-53021A. static pressure (PS3) for Single Annular Com-
bustor (SAC) applications and at least 300°F
The purchaser may refer to the Qualified Parts (167°C) below the bubble point temperature
List (QPL-53021) for a summary of approved for Dry Low Emissions (DLE) applications.
stabilizer additives used in the long-term stor-
age of diesel and distillate fuels. This publica- A2-3.2 Filtration
tion is periodically revised, and is available
from the U.S. Government Printing Office. The following filtration levels will result in
the intent of the fuel specification filtration
Additives that have been reviewed by GE and levels being satisfied. Filtration is most com-
considered acceptable are: monly expressed by filter beta ratio (β) at a
specified particle diameter. The standard of
Biocides: (See supplier documentation for beta ratio at a particle size is β = (total number
concentration recommendations) particle at diameter or greater into filter/parti-
NALCO 5309 cles at diameter or greater through filter).
Biobor JF Thus, for a given particle size, efficiency in
Kathon FP 1.5 terms of beta ratio is (ε = [1 - 1/β] x 100%).
A2-3 Additional Requirements Total Particulate 10 mg/gal max (2.64 mg/l)
A2-3.1 Fuel Temperature Filtration β = 200 (ε = 99.5%) min
Requirements @ 5μ or less
The minimum temperature of liquid fuel sup- A2-4 Fuel Handling
plied to the gas turbine shall be the greater of:
True distillate fuel as refined has low water,
(a) 20°F (11°C) above the wax point dirt, and trace metal contaminant levels that
(cloud point) temperature of the can be maintained with careful transportation,
fuel. handling, and storage methods. Most contami-
nation occurs during transportation of fuel.
or
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Since fuel can be contaminated during trans- Duplex, primary strainers (150-200 micron
portation from the refinery to the site, auxil- absolute) should be located between the off-
iary fuel cleanup equipment should be loading facility and the raw fuel storage tanks.
available to restore the fuel quality. Avail- Duplex, secondary filters (50-100 micron
able purification equipment includes centri- absolute) should be located between the raw
fuges and electrostatic dehydrators. In fuel storage tanks and the final fuel treatment
addition to potential hot corrosion from salt system. All fuel storage tanks must have inlets
in the water, water accumulated in the bot- at the bottom of the tank. All fuel day storage
tom of a storage tank can also cause prob- tanks should be provided with a floating suc-
lems. Micro-organisms tend to grow at the tion. The distance between the inlet and outlet
water/fuel interface, generating both chemi- should be maximized.
cals corrosive to metals in the fuel system
and also slime that can plug fuel filters. In After filling any tank or adding fuel to it, a set-
marine applications, shipboard systems that tling time of 24 hours should be allowed
allow recycling fuel from the service tanks before taking fuel from that tank. Initially,
through the centrifugal purifiers are recom- water and sludge should be drained from all
mended. storage tanks on a daily basis. After experi-
ence is gained with a given fuel and fuel
When liquid fuel is supplied by barges or source, the frequency of draining may be
other bulk modes of transportation, it should adjusted by the customer.
be pumped directly into raw fuel storage
tanks, and must be conditioned/treated before A2-4.1 Additional Requirements for
being placed in one of two clean fuel day stor- Bio-Diesel Fuel
age tanks from which gas turbine will be sup-
plied. Redundant, clean day fuel storage tanks • B100 fuel must be stored at temperatures
are recommended to provide a primary settled at least 10°F (5.6°C) above the cloud
fuel supply and to allow tank repair and/or point. Fuel provided to the gas turbine is to
cleaning with minimum downtime. Storage be heated to a 100°F (37.8°C). Failure to
tanks must be constructed of corrosion-resis- maintain these temperatures can cause the
tant materials or appropriately lined to mini- fuel to gel resulting in fuel filter and fuel
mize internally formed contaminants. Fuel nozzle plugging and fuel pump malfunc-
shall not be transported, stored, or handled in tion.
system components containing copper, e.g.,
• B100 fuel should not be stored for more
ships that have copper heating coils, or storage
than 6 months before use.
tanks coated with zinc. Neither copper nor
zinc is normally found in refined fuels such as • Before using or storing B100 fuel, fuel
diesel and naphtha, but should they be present, tanks and the fuel system should be thor-
they can cause fuel degradation and additional oughly cleaned. Failure to do so could
engine maintenance. No fuel should be used cause fuel filter and fuel nozzle plugging
that contains detectable amounts of copper or and fuel pump malfunction resulting from
zinc. the cleaning effect of B100 fuel.
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• For DLE applications, the B100 fuel vis- • At the port where the fuel is delivered
cosity must not exceed 3cs for starting. before unloading
This may require fuel temperature greater
than 100°F (37.8°C). • From the pipeline just upstream of the raw
fuel storage tanks as the fuel is being
B100 will degrade, soften, or seep through added to the tanks.
some hoses, gaskets, seals, elastomers, glues,
and plastics with prolonged exposure. Nitrile After the fuel is treated/conditioned, samples
rubber compounds, polypropylene, polyvinyl, should be taken and analyzed at both the inlet
and Tygon materials are particularly vulnera- and outlet of the fuel treatment system. Fuel
ble to B100. Materials such as Teflon, Viton, exiting the system must meet the fuel specifi-
fluorinated plastics, and nylon are compatible cation. This should be confirmed before the
with B100. It is advisable to set up a monitor- fuel is placed in clean fuel day storage tanks.
ing program to visually inspect fuel system Fuel samples should be taken and analyzed to
equipment once a month for leaks, seeps, and ensure that the fuel discharged from these
seal decomposition. It would be wise to con- tanks and at a practical location at, or just
tinue these inspections even after one year, as upstream of, the gas turbine fuel manifold
the experience is still relatively limited with flange meets the specification.
B100. Brass, bronze, copper, lead, tin, and
zinc may accelerate the oxidation of biodiesel For all fuel sampling, sufficient samples (min-
fuels and potentially create fuel insolubles imum of three) must be taken to ensure that a
(sediments) or gels and salts when reacted representative sample is obtained. Samples
with some fuel components. A detailed review should be taken at different levels in large vol-
of both the gas turbine and the package fuel ume tanks and at equally spaced time intervals
systems must be completed before long-term during fuel delivery or fuel treatment. To
use of B100 fuel is initiated. avoid contamination, all samples should be
obtained in clean plastic bottles. Fuel samples
A2-5 Fuel Sampling taken should be analyzed to meet all GE liquid
fuel requirements. If fuel samples taken after
A well thought out fuel sampling protocol will the above recommendations have been imple-
ensure that quality fuel is delivered to the mented indicate that the fuel system does not
engine. For each delivery, fuel samples should provide fuel per the requirements, the cus-
be taken and analyzed at the following loca- tomer must change his fuel source or modify
tions: the fuel treatment system. The end user is
responsible for ensuring that the fuel meets the
• At the refinery before loading requirements.
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Table A2-1. Liquid Fuel Property Requirements
Property Limit Test Method
Ash, %, maximum 0.01 ASTM D482 (IP 4), or ISO 6245
Sulfur, %, maximum 1.0 a ASTM D129 (IP 336), D4294 (IP 61),
D1552, D2622, D1266, D7039, D5453,
or ISO 8754
Vanadium, ppm, maximum 0.2 ASTM D3605, D7111, D6728, or ISO
6891 (V only)
Sodium, Potassium, and Lithium, ppm, maximum 0.2b, c ASTM D3605d, D7111, or D6728
Lead, ppm, maximum 1.0 ASTM D3605, D7111, or D6728
Calcium, ppm, maximum 2.0 ASTM D3605, D7111, or D6728
Phosphorus, ppm, maximum e 2.0 ASTM D4951
Hydrogen content, %, minimum 12.7f, g ASTM D1018, D3701 (IP 338), or D5291
Demulsification, minutes, maximum 20.0 ASTM D1401 and Note 3 therein, or
D2711 (if viscosity > 90 cSt)
Particulates, mg/gal, maximum 10.0 ASTM D2276 (IP 216), D5452, or D6217
Water and Sediment, volume %, maximum 0.10 h ASTM D2709, D1796, D6304, or ISO
3734
Flash point, °F, maximum 200°Fi ASTM D93 (IP 34), D56, D3194, D3828,
(93.3°C) D3941 (IP 170), or ISO 2719
Copper corrosion, maximum No. 1j ASTM D130 (IP 154), D1838, ISO 2160,
or ISO 6251
Asphaltenes, %, maximum None ASTM D6560 or IP 143
Detectableg
Viscosity, cs ASTM D445
Minimum 0.5
Maximum, Starting 6.0
Maximum, Running 12.0
Distillation: ASTM D86
10% Point, °F (°C) Report
50% Point, °F (°C) Report
90% Point, °F (°C) 675 (357)k
End Point, Point, °F (°C)
725 (385)k
Carbon residue, %, maximum (100% sample) 1.0 ASTM D524 or IP 4262
Carbon residue, %, maximum (10% Ramsbottoms) 0.25 ASTM D524 or IP 4262
Specific Gravity Report ASTM D287, D1298, D1480, or D4052
Cloud Point Report ASTM 2500
Lower Heating Value (LHV) BTU/LB Report ASTM D240 or D4809
Nitrogen (Fuel Bound Nitrogen), % Report ASTM D5291, D4629, D5762, or D3228
ASTM - ASTM International ISO - International Organization for Standardization IP - Institute of Petroleum UK
When an IPxxx in parentheses follows immediately after an ASTM Dyyy, it is the identical method. Example ASTM
D130 (IP 154). If the IPxxx is listed without parentheses it is not identical, but is an acceptable alternative method.
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Table A2-1. Liquid Fuel Property Requirements (Continued)
Property Limit Test Method
Notes:
a. Fuels with a higher sulfur content can be burned. Impact on HSRI (Hot Section Repair Interval) will be dependent
upon alkali metals present in the fuel, inlet air, and injected water and upon engine operating temperature. Consult
GE for review of higher sulfur fuels.
b. This limit is considered to include all alkali metals, e.g., potassium and lithium, as well as sodium. Experience,
however, has shown that sodium is generally the predominant alkali metal.
This limit also assumes zero alkali metals in the inlet air or injected water or steam. When actual levels are above
zero, the maximum allowable sodium content of the fuel must be reduced in accordance with the following rela-
tionship:
ppm Na in Inlet Air x Air/Fuel Ratio
+ ppm Na in Water or Steam x Water or Steam/Fuel Ratio
+ ppm Na in Fuel
Total fuel equivalence for sodium from all sources not to exceed 0.2 ppm.
c. For non marinized engines (except for LM6000), the total amount of alkali metals from all sources shall not exceed
0.1 ppm.
d. To achieve the level of sensitivity for detection of sodium to the level required, an atomic absorption spectrometer
or a rotating disk spectrometer may be necessary.
e. Phosphorus testing applies to Bio-diesel blends only.
f. Care must be taken with the more viscous fuels to ensure that the minimum hydrogen content is met.
g. Fuels with Hydrogen content lower than 12.7% have been approved for use in certain applications with specific
restrictions. These fuels require a development test program for the applicable engine model before approval would
be considered. Asphaltene testing applies only to such fuels. In general, fuels with Hydrogen content less than 10%
have not been shown to be acceptable.
h. For marine gas turbines using a hydromechanical main fuel control, the limit is 40 ppm.
i. Legal limits and applicable safety regulations must be met; however, it should be noted that use of fuels having a
flash point in excess of 200°F (93.3°C) may result in unsatisfactory starting characteristics. Blending for enhance-
ment of spark ignition or use of alternate fuels may be required for starting.
j. Copper corrosion test conditions are 2 hours at 212°F (100°C).
k. LM6000 SAC models may not operate without water injection above 15MW power, if the distillation end point
temperature is above 675°F (357°C).
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Appendix A3
Requirements for Water and Steam Purity for Injection in
AeroDerivative Gas Turbines
This document establishes the purity require- ASTM D3370 Standard Practices for
ments for water for NOx suppression and Sampling Water from
SPRINT® injection into gas turbine engines Closed Conduits
and for Steam for injected into the gas turbine
ASTM D4327 Anions in Water by
whether for NOx suppression or power aug-
Chemically Suppressed
mentation.
Ion Chromatography
For the purpose of this specification, the fol- ASTM D5391 Electrical Conductivity
lowing definition shall apply: and Resistively of a
Flowing High-Purity
NOx Suppression Water - Water introduced Sample
into the engine combustor for the purpose of
suppressing the oxides of nitrogen (NOx) in ASTM D5464 Standard Test Method for
the engine exhaust gases. This does not pH of Water with Low
include any boiler feed or make up water for Conductivity
steam generation. ASTM D5542 Trace Anions in High-
Purity Water by Ion
SPRINT® Water - Water introduced into the
Chromatography
engine inlet or into the high pressure compres-
sor inlet for purpose of power enhancement. ASTM D5907 Standard Test Method
for Filterable and Non-
Steam - Steam that is injected into the com-
Filterable Matter in Water
bustion for NOx suppression or injected into
the compressor rear frame or LP Turbine for Environmental Protection Agency (EPA)
power augmentation on certain LM modules.
Test Methods.
A3-1 Applicable Documents EPA 150.1 pH Electrometric
Available from ASTM International, EPA 200.7 Metals & Trace Elements
100 Barr Harbor Drive, P.O. Box C700,
West Conshohocken, PA, 19428-2959 USA EPA 300.0 Determination of
(http://www.astm.org). Inorganic Anions by
Ion Chromatography
ASTM D1066 Standard Practice for
Sampling Steam
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A3-2 Water Sampling A3-3 Water Purity Requirements
Requirements
The water shall meet the following require-
The sampling shall be in accordance with ments when tested in accordance with the des-
ASTM D3370. A minimum of 1 gallon or ignated test methods:
4 liters shall be supplied.
Limit Test Method
Total Suspended Solids and 5 ASTM D5907(1), EPA
Total Dissolved Solids, mg/L, max 5
160.1(1), EPA 160.2(1)
pH(2) 6.0 - 8.0 ASTM D5464 or
EPA 150.1
Conductivity(2), μS/cm at 25°C < 1.0 ASTM D5391(3)
Sodium + potassium, ppm, max See 3.3 EPA 200.7
Silica (SiO2), mg/L, max 0.1(4) EPA 200.7
ASTM D5542,
Chlorides, mg/L, max 0.5 ASTM D4327, or
EPA 300.0
ASTM D5542,
Sulfates, mg/L, max 0.5 ASTM D4327, or
EPA 300.0
(1) Use twice the recommended volume of sample
(2) pH and Conductivity shall be measured when water is free of carbon dioxide
(3) Flowing Sample Method B
(4) If gas fuel utilized contains Siloxanes, limit is 0.05 mg/l (Ref MID-TD-0000-1)
A3-4 Sodium & Potassium Limits Where:
in Water or Steam ppmFuel = Parts per million Na + K in Fuel
ppmAir = Parts per million Na + K in Air
The maximum amount of Na + K allowed in
the water or steam injected into the engine ppmWater = Parts per million Na + K in
depends upon the total Na + K contamination Water
from all sources; i.e., from the fuel, air, water ppmSteam = Parts per million Na + K in
and steam. The maximum Na + K allowed is Steam
determined from the equation:
A/F = Air/Fuel Ratio (Wt. Basis)
(ppmFuel)+(ppmAir)*A/F+(ppmWater)*W/F W/F = Water/Fuel Ratio (Wt. Basis)
+(ppmSteam)*S/F = 0.2 ppm. S/F = Steam/Fuel Ratio (Wt. Basis)
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A3-5 Water Filtration • Total Solids
Requirements
The maximum total solids depends on the stem/
Filtration is most commonly expressed by fil- fuel weight ratios at which the gas turbine is to
ter beta ratio (β) at a specified particle diame- operate in the specific application. The value is
ter. The standard of beta ratio at a particle size determined from the following figure. Contam-
is β = (total number particle at diameter or inant size shall not exceed 250 microns. With
greater into filter/particles at diameter or the exception of silica, there is no differentia-
greater through filter). Thus, for a given parti- tion between types of solids as long as other
cle size, efficiency in terms of beta ratio is limitations of this section are met. Interpreta-
[ε = (1 - 1/β) x 100%]. The filtration level tion of Figure 1 should be made as follows:
shall be a beta ratio of 200 minimum
a. Calculate maximum steam-to-fuel ratio by
(efficiency of 99.5%) at 20μ or less.
dividing total (CDP & fuel nozzle) high
A3-6 Steam Requirements pressure steam flow by fuel flow (WF36)
for site operating conditions. Where steam
A3-7 Steam Purity flow may vary widely, operating condition
with highest steam-to-fuel ratio should be
The steam shall meet the following require- used.
ments when tested in accordance with the des-
b. From curve, determine maximum solids
ignated test methods:
permissible and apply this limit to steam
• Sodium + Potassium (Na + K) - See supplied to gas turbine.
paragraph A3-4
Silica in the steam is limited to 20 ppb.
• Total Conductivity (Cation + Anion)
A3-8 Steam Sampling
Normal : <1.5 μS/cm (95% of operation
Steam samples should be taken in accordance
time)
with ASTM D1066.
Abnormal : <2.0 μS/cm (5% of operation
time)
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Figure 1. Steam Contamination Maximum Solids
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Appendix A4
Compressor Cleaning Water Purity Specification for GE Aircraft
Derivative Gas Turbines in Industrial Applications
This specification establishes the requirements A4-1 Applicable Documents
for purified water for use in cleaning the com-
pressor of gas turbine engines where the intent The following documents shall form a part of
is to restore performance by removing the this specification to the extent defined herein.
buildup of deposits from compressor compo- Unless an issue is stipulated, the latest revision
nents. The water quality defined in this speci- shall apply.
fication applies to water used in both on-line
compressor cleaning and crank-soak compres- Available from ATSM International,
sor cleaning. 100 Barr Harbor Dr., P.O. Box C700,
West Conshohocken, PA, 19428-2959 USA
For the purpose of this specification, the fol- (http://www.astm.org).
lowing definitions shall apply:
ASTM D1293 Tests for pH of Water
On-line Compressor Cleaning - A method of
removing the buildup of deposits on compres- ASTM D3370 Practices for Sampling
sor components while the engine is operating. Water
On-line cleaning is accomplished by spraying
cleaning solution into the inlet of the engine ASTM D4191 Test for Sodium in Water
while the engine is operating. by Atomic Absorption
Spectography
Crank-Soak Compressor Cleaning - A
method of removing the buildup of deposits ASTM D4192 Tests for Potassium in
on compressor components while the engine is Water by Atomic
motored by the starter. Crank-soak cleaning is Absorption Spectography
accomplished by spraying cleaning solution
ASTM D5907 Tests for Filterable and
into the inlet of the engine while the engine is
operating unfired at crank speed. Non-Filterable Matter in
Water
Liquid Detergent - A concentrated solution
A4-1.1 Environmental Protection
of water-soluble surface active agents and
emulsifiable solvents. Agency (EPA) Test Methods
EPA 160.3 Residue, Non-Filterable
Cleaning Solution - A solution of emulsion of
and Total Suspended Solids
liquid detergent and water or a water and anti-
freeze mixture for direct engine application. EPA 150.1 pH Electrometric
The recommended dilution of liquid detergent
and water shall be specified by the liquid EPA 200.7 Metals & Trace Elements
detergent manufacturer.
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A4-2 Sampling Requirements A4-4 Filtration Requirements
Sampling shall be in accordance with Filtration is most commonly expressed by fil-
ASTM D3370. A minimum sample of 1 gallon ter beta ratio (β) at a specified particle diame-
or 4 liters shall be supplied. ter. The standard of beta ratio at a particle size
is β = (total number particle at diameter or
A4-3 Chemical Requirements greater into filter/particles at diameter or
greater through filter). Thus, for a given parti-
The water shall meet the following require- cle size, efficiency in terms of beta ratio is
ments when tested in accordance with the des- [ε = (1 - 1/β) x 100%]. The filtration level
ignated test method. shall be a beta ratio of 200 minimum
(efficiency of 99.5%) at 100μ or less.
Limit Test Method
Total matter, ppm, max 100 ASTM D5907 or EPA 160.3
pH 6.5 - 8.5(1) ASTM D1293 or EPA 150.1
Sodium + potassium, ppm max 25 ASTM D4191 &
ASTM D4192 or EPA 200.7
Note(1): pH of 6.5 - 8.5 is desired, 6.0 - 8.5 is permitted.
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Appendix A5
Liquid Detergent for Compressor Cleaning for GE Aircraft
Derivative Gas Turbines
This specification establishes the requirements ASTM D445 Standard Test Method for
for liquid detergents used to prepare cleaning Kinematic Viscosity of
solutions for cleaning the compressors of gas Transparent and Opaque
turbine engines, where the intent is to restore Liquids
performance by removing the buildup of
deposits on compressor components. Such ISO 3104 Determination of
deposits include salt, soils, and oils that may Kinematic Viscosity and
be ingested from the atmosphere. Calculation of Dynamic
Viscosity
The cleaning process shall be carried out by
spraying the cleaning solution into the bell- ARP 1795 Stress-Corrosion of
mouth of the engine while the engine is run- Titanium Alloys, Effect
ning at power (on-line cleaning) or while the of Cleaning Agents on
engine is being cranked (crank-soak cleaning). Aircraft Engine Materials
For the purposes of this specification, the fol- AMS 1424 Deicing/Anti-Icing Fluid,
lowing definitions shall apply: Aircraft (Newtonian - SAE
Type I)
Liquid Detergent - A concentrated solution
of water-soluble surface active agents and A5-2 Detergent Properties
emulsifiable solvents.
A5-2.1 Composition
Cleaning Solution - A solution or emulsion of
liquid detergent in water or water and anti- The chemical composition of the detergent is
freeze mixture for direct engine application. not limited, other than as specified herein.
Recommended dilution of detergent and water
A5-2.2 Biodegradability
shall be determined by the liquid detergent
manufacturer. Use of detergent/cleaning solution shall con-
form to local regulations for water pollution.
A5-1 Applicable Documents Biodegradable ingredients are recommended.
The following documents shall form a part of A5-2.3 Toxicity
this specification to the extent defined herein.
Unless a specific issue is specified, the latest Use of the liquid detergent/cleaning solution
revision shall apply. shall conform to local regulations for indus-
trial hygiene and air pollution. Use of nontoxic
ASTM D88 Standard Test Method for ingredients is recommended.
Saybolt Viscosity
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A5-2.4 Health and Safety Information liquid detergent manufacturer's recommended
dilution in the following antifreeze solution
The liquid detergent manufacturer shall make after 2 hours at 10°F ± 3 (-12°C ± 2).
available health and safety information for the
liquid detergent as required by applicable • Monopropylene glycol (MPG)
local, state, and federal regulations.
See paragraph A5-6 for more information
A5-2.5 Solids regarding liquid detergent and antifreeze mix-
tures.
The liquid detergent shall contain no particles
larger than 20 microns. A5-3.1.4 Hard Water Compatibility
A5-2.6 Physical and Chemical The liquid detergent shall show no separation
Properties or layering when mixed with synthetic hard
water prepared in accordance with paragraph
The liquid detergent shall meet the following
A5-4.2.
test requirements.
A5-3.1.5 Acid and Alkali Acceptance
A5-3 Test Requirements
The liquid detergent shall show no separation,
Requirements are defined for liquid detergents layering, or precipitation when tested in acidic
and for cleaning solutions. or alkali media in accordance with paragraph
A5-4.3.
A5-3.1 Liquid Detergent
A5-3.1.6 Salt Water Tolerance
A5-3.1.1 Residue or Ash Content
The liquid detergent shall show no separation
Residue or ash content shall not exceed 0.01% or gelling when mixed with 3.5% salt water in
when tested in accordance with paragraph accordance with paragraph A5-4.4.
A5-4.1.
A5-3.1.7 Viscosity
A5-3.1.2 Low-Temperature Stability
The liquid detergent shall have a viscosity of
The liquid detergent shall show no evidence of 50 to 200 SUS at 77°F (25°C) when tested in
separation of component parts when main- accordance with ASTM D88, or 7.4 to
tained at 40°F ± 3 (5°C ± 2). It is highly desir- 43.3 cSt when measured per ASTM 445 or
able although not mandatory that the fluid ISO 3104.
shall remain liquid below 32°F (0°C).
A5-3.1.8 pH
A5-3.1.3 Cold Weather Solution
The pH of the liquid detergent as received
Compatibility
shall be from 6.5 to 8.5 when measured with a
The liquid detergent shall show no separation, suitable pH meter employing a glass electrode.
layering, or precipitation when mixed to the
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A5-3.2 Cleaning Solution a muffle furnace at 1040 to 1100°C for
2 hours, cool in a desiccator, and weigh.
A5-3.2.1 Corrosive Elements
Percent residue or ash = (100 x A) / W
Maximum levels of elements in the cleaning
solution, which may promote various types Where: A = grams of residue
of corrosion, shall be no greater than as W = grams of sample
shown in Table A5-1 when analyzed by meth-
ods in paragraph A5-4.5. A5-4.2 Hard Water Compatibility
Table A5-1 Maximum Corrosives Limit A5-4.2.1 Preparation of Synthetic Hard
Total Alkali Metals (Sodium +
Water
25 ppm max
Potassium + Lithium, etc.)
A hard water solution is prepared by dissolv-
Magnesium + Calcium 5 ppm max ing the following in 1 liter of just boiled and
Vanadium 0.1 ppm max cooled distilled water:
Lead 0.1 ppm max a. 0.20 ± 0.005 gram calcium acetate, reagent
Tin + Copper 10 ppm max grade Ca (C2H3O2)2 H2O.
Sulfur 50 ppm max b. 0.15 ± 0.005 gram magnesium sulfate,
Chlorine 40 ppm max reagent grade MgSO4 7 H2O.
A5-4.2.2 Hard Water Test
A5-3.2.2 pH
Five ml of liquid detergent shall be added to a
The pH of the cleaning solution shall be from
clean 50-ml cylinder. Add 45 ml of synthetic
6.5 to 8.5 when measured with a suitable pH
hard water and mix well. Examine the solution
meter employing a glass electrode.
for compatibility after 16 hours at 77°F ± 5
A5-4 Test Methods (25°C ± 3).
A5-4.3 Acid and Alkali Acceptance
A5-4.1 Residue or Ash Content
The liquid detergent shall be mixed with dis-
Weigh 10 ± 0.1 gram sample of liquid deter-
tilled water in accordance with the liquid
gent in a weighed 30 ml porcelain crucible.
detergent manufacturer's recommended dilu-
Heat gently to volatilize any water or sol-
tion. To 50 ml of the solution, add 1 ml of 75%
vents. (Crucible may be placed in air oven at
phosphoric acid. To another 50 ml of the solu-
105°C ± 2 for 24 hours, followed by 240°C ±
tion, add 5 ml of 75% phosphoric acid. To
2 for 24 hours to ensure all volatile matter is
another 50 ml of the solution, add 1 ml of 50%
evaporated.) Finally, ignite contents over
potassium hydroxide. Let all three mixtures
Bunsen Burner, first at low temperature under
stand for 1 hour at 77°F ± 5 (25°C ± 3) and
good oxidizing conditions until all ignitable
then examine for acid or alkali acceptance.
material is consumed, then place a crucible in
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A5-4.4 Salt Water Tolerance A5-6 Cold Weather Usage
Prepare a 3.5% by weight solution of sodium In cold weather, liquid detergent must be
chloride in distilled water. Add 15 ml of salt added to antifreeze mixture rather than to
solution to 35 ml of liquid detergent and let water alone. At present, the only acceptable
stand for 1 hour at 77°F ± 5 (25°C ± 3). Exam- antifreeze solutions are:
ine for salt water tolerance.
• Monopropylene glycol (PG)
A5-4.5 Elemental Content
Monopropylene glycol (PG) must be per AMS
Elemental content shall be determined using 1424 and may be used down to 20°F (-7°C).
the following methods:
Antifreeze mixtures are shown in Table A5-2.
Element Method The liquid detergent manufacturer must spec-
Sulfur, Phosphorus Inductively Coupled
ify if the antifreeze specified above is not
Plasma Spectroscopy - compatible with the liquid detergent.
Spectroscopy (ICP-AES)
The use of non-isopropyl alcohol, ethylene
Chlorine Microcoulometric filtration glycol, or additives containing chlorine,
Sodium, Potassium Atomic Absorption (AA) sodium, or potassium are not permitted since
they may attack titanium and other metals in
Other metals ICP-AES or AA
the gas turbine.
A5-5 Compatibility It is extremely important that the liquid deter-
gent and antifreeze solution be a homoge-
A5-5.1 Engine Materials neous mixture when sprayed into the gas
turbine. If after 2 hours the liquid detergent
Use of the detergent gas turbine cleaner shall and antifreeze solution separates (see
not have adverse effects on engine system paragraph A5-3.1.3), agitation of the mixture
materials such as titanium stress corrosion, hot in the water-wash tank is permissible. How-
corrosion of turbine components, or damage to ever, the liquid detergent manufacturer shall
lubrication system components. specify that agitation is required.
A5-5.2 Titanium Stress Corrosion Table A5-2 Water-Wash Antifreeze Mixtures
A titanium stress corrosion test in accordance Compressor Washing and Rinsing
with ARP 1795, or equivalent, may be run on Antifreeze Mixtures
the liquid detergent at the discretion of GE. Outside Air Monopropylene
Temperature, Glycol (PG) H 2O
°F (°C) % Vol % Vol
20 to 50 (-7 to 10) 20 80
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Appendix A6
Lubricating Oil Guidance for GE Aero Engines
This document provides the requirements and some GE Aeroderivative products as
application guidelines for selection and use of specified in the applicable operation and
lubricating oils in GE Marine and Industrial maintenance (O&M) manual.
Aeroderivative applications.
A6-2 Applicable Documents
NOTE: Industry standards are moving toward the
improvements offered by SAE AS5780. This The following documents form a part of this
broadens the fitness criteria definition to include specification to the extent defined herein. Unless
the improvements in traceability, change control, a particular issue is stipulated, the latest revision
and bench test standards. shall apply.
Oil products continue to evolve and improve. A6-2.1 Oil Specifications
Customers should consult with oil suppliers
regarding the details of their product offerings. MIL-PRF-23699 - Lubricating Oil, Aircraft
Turbine Engines, Synthetic Base
A6-1 Oil Specifications
MIL-PRF-7808 - Lubricating Oil, Aircraft
As a starting point, oils conforming to the specifi- Turbine Engines, Synthetic Base
cations listed in Section A6-2.1 are candidates for SAE AS5780 - Specification for Aero and
use in GE aircraft derivative gas turbines. Please Aero-Derived Gas Turbine Engine Lubricants
note, each of the specifications contain sub-
classes that differ in their performance goals. Fur- A6-3 Recommendations
thermore, oils conforming to the same specifica-
tion and sub-class are not necessarily identical in A6-3.1 Oil Mixing
every aspect of performance. For example, an oil
may be superior with respect to coking, but show Oil mixing is discouraged because it creates a
a relatively poor compatibility with O-ring mate- condition that has not been thoroughly evaluated
rials, while passing the specification require- by testing and can create conditions that
ments. Meanwhile other approved oils may be adversely affect lubrication.
superior in both respects.
NOTE: MIL-PRF-7808 oils are not compatible
As such, there are many factors that deserve con- with either MIL-PRF-23699 or SAE AS5780 oils.
sideration in order to narrow the selection. They
include, but are not limited to: A6-3.2 Material Compatibility
• A particular oil product needs to be Oil specification MIL-PRF-23699 includes high
listed on the Qualified Product List thermal stability (HTS) oil formulations designed
(QPL) for the specification. to resist degradation over extended periods at
higher temperatures. The SAE AS5780 specifica-
• GE prefers the 5 cSt grades conforming tion includes high performance capability (HPC)
to MIL-PRF-23699 STD or SAE oils. Service experiences with some HTS/HPC
AS5780 SPC over the 3 cSt grade of oils in GE Aviation Products have demonstrated
MIL-PRF-7808. Approval by GE of excessive swelling and softening of traditional
use of oil to MIL-PRF- 7808 on a AMS-R-83248 (FKM) elastomer seals used in the
site-by-site basis is a requirement for lube systems. The level of degradation caused by
A-35
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
MID-TD-0000-6 GE Energy
May 2012 GE Aviation
some HTS/HPC oils is linked to service pressure d. Oil Property Stability and Perfor-
and temperatures. mance
Reference 1 provides an excellent description of 2. The oil manufacturer should show evi-
the chemistry and physics of this well-known dence of suitability for anticipated per-
industry issue. formance beyond 25,000 hours to
demonstrate to their prospective cus-
GE Aeroderivative engines continue to use tradi- tomers that these requirements have
tional AMS-R-83248 (FKM) seals. HTS/HPC been met.
oils being considered for use in GE Aeroderiva-
tive products must be reviewed by the operator Engine boroscope inspections, partial engine dis-
and oil supplier for compatibility with these assembly, used oil analyses and O-ring condition
materials in the particular engine type, environ- evaluation may be required to demonstrate that
ment, and type of service for which usage is being the above requirements are met.
considered.
The following oils have been widely used in GE
A6-4 Fitness Criteria Aeroderivative Products with general customer
satisfaction:
In order for oils to be considered suitable for use
in GE Aeroderivative applications, the following AeroShell 500TM (AS5780 SPC)
criteria must be met. AeroShell 560TM (AS5780 SPC)
At a minimum, the oils must be:
BP 2380TM (AS5780 SPC)
1. Approved to MIL-PRF-23699 or AS5780. Mobil Jet Oil IITM (AS5780 SPC)
OR Turbonycoil 600TM (AS5780 SPC)
2. Approved to MIL-PRF-7808 (for exist-
ing successful applications. Not recom- BP 2197TM (AS5780 HPC)
mended for future applications). Mobil Jet Oil 254TM (AS5780 HPC)
AND have demonstrated the following: The above list is not intended to be comprehen-
sive and does not imply any GE endorsement.
1. The Oil Manufacturer should demonstrate Ultimately, the operator and oil supplier are
suitability to the operator by evaluation of responsible for lubrication selection.
the oil for a minimum of 25,000 hours
under appropriate operational and cli- A6-5 References
matic conditions. Suitability should be
demonstrated with respect to: 1. SAE Technical Series 2001-01-2974, “Fluo-
a. Seal material compatibility parity to roelastomer Compatibility with Advanced
MIL-PRF-23699 STD or AS5780 Jet Engine Oils”. E.W. Thomas (available at
SPC class oils specifically relating to http://papers.sae.org/)
AMS-R-83248 (Viton A) elastomer
seals
b. Coking
c. Corrosion issues
A-36
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 is a registered trademark of the General Electric Company.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059
Volume II
ON-SITE OPERATION AND MAINTENANCE MANUAL
FOR
GENERAL ELECTRIC LM6000® PC SERIES
GAS TURBINES
GE INDUSTRIAL
AERODERIVATIVE
GAS TURBINES
GE INDUSTRIAL AERODERIVATIVE GAS TURBINES
GENERAL ELECTRIC COMPANY
CINCINNATI, OHIO 45215-6301
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
Highlights of GEK 105059 Change 6
WP/SWP LOCATION DESCRIPTION OF CHANGE
0001 00 Table 2 Apply general updates to Special Tools list, added,
deleted, and updated part numbers, nomenclature,
category, and WPs.
2413 00 Paragraph 9 Added step A.(3)
2510 00 Paragraph 3 Added new support equipment
Figure 3 Updated
2610 00 Paragraph 6 Added PN in step N.(1)
2611 00 Paragraph 3 Added information to item in Part No. column and
added new support equipment
2614 00 Paragraph 2 Deleted reference material
Paragraph 6 Updated bullet Note before step A
2710 00 Paragraph 3 Deleted item and updated three items in Part No.
column
2811 00 Paragraph 1 Deleted step B
Paragraph 2 Added new reference material
Paragraph 6 Added new steps A and B and renumbered subse-
quent steps
Paragraph 7 Added new steps Q and R
3017 00 Paragraph 3 Updated PN and added new support equipment
Paragraph 6 Deleted information in step A
Figure 1 Updated title (Sheets 1 and 2)
4015 00 Paragraph 9 Updated steps A and C.(1)
Paragraph 10 Added figure reference in step C
Figure 4A Added (Sheets 1 and 2)
Table 1 Added entire item 6
Figure 18B Changed (Sheet 1)
4027 00 Paragraph 3 Updated support equipment item and added
Caution
Paragraph 6 Deleted steps B and E
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059
Volume II
ON-SITE OPERATION AND MAINTENANCE MANUAL
FOR
GENERAL ELECTRIC LM6000® PC SERIES
GAS TURBINES
GE INDUSTRIAL
AERODERIVATIVE
GAS TURBINES
GE PROPRIETARY INFORMATION
THE INFORMATION CONTAINED IN THIS DOCUMENT IS GE PROPRIETARY
INFORMATION AND IS DISCLOSED IN CONFIDENCE. IT IS THE PROPERTY OF GE AND
SHALL NOT BE USED, DISCLOSED TO OTHERS, OR REPRODUCED WITHOUT THE
EXPRESS WRITTEN CONSENT OF GE, INCLUDING, BUT WITHOUT LIMITATION, IT IS
NOT TO BE USED IN THE CREATION, MANUFACTURE, DEVELOPMENT, OR DEVIATION
OF ANY REPAIRS, MODIFICATIONS, SPARE PARTS, DESIGN, OR CONFIGURATION
CHANGES OR TO OBTAIN FAA OR ANY OTHER GOVERNMENT OR REGULATORY
APPROVAL TO DO SO. IF CONSENT IS GIVEN FOR REPRODUCTION IN WHOLE OR IN
PART, THIS NOTICE AND THE NOTICE SET FORTH ON EACH PAGE OF THIS
DOCUMENT SHALL APPEAR IN ANY SUCH REPRODUCTION IN WHOLE OR PART. THE
INFORMATION CONTAINED IN THIS DOCUMENT MAY ALSO BE CONTROLLED BY U.S.
EXPORT CONTROL LAWS. UNAUTHORIZED EXPORT OR REEXPORT IS PROHIBITED.
ALL TECHNICAL DOCUMENTATION AND INFORMATION CONTAINED HEREIN 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 DOCUMENT 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.
COPYRIGHT (2013) GENERAL ELECTRIC COMPANY, USA
GE INDUSTRIAL AERODERIVATIVE GAS TURBINES
GENERAL ELECTRIC COMPANY
CINCINNATI, OHIO 45215-6301
15 May 2008
Change 6 15 August 2013
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II NOTE GE Industrial AeroDerivative Gas Turbines
These instructions are not intended to cover all details or variations in
equipment, or to provide for every contingency connected with instal-
lation, replacement, and maintenance. If more information is desired,
or if problems arise which are not covered herein, contact General
Electric Customer Service.
NUMERICAL INDEX OF EFFECTIVE PAGES AND WORK PACKAGES
List of Current Changes
Revision.......... 0 .......... 15 May 2008 Change .......... 4 .......... 15 August 2011
Change .......... 1 .......... 30 August 2008 Change .......... 5 .......... 15 August 2012
Change .......... 2 .......... 30 August 2009 Change .......... 6 .......... 15 August 2013
Change .......... 3 .......... 15 August 2010
Total number of pages in this volume is 1586 consisting of the following:
Page No. Change No.
Title ....... 6
A to B/(C Blank) ....... 6
i to iv ....... 6
WP/SWP No. Change No. WP/SWP No. Change No. WP/SWP No. Change No.
WP 0001 00 ........ 6 WP 1514 00 ........ 0 WP 1910 00 ......... 0
WP 1110 00 ........ 1 WP 1515 00 ........ 0 WP 1911 00 ......... 0
WP 1111 00 ........ 0 SWP 1515 01 ........ 0 WP 1912 00 ......... 0
WP 1112 00 ........ 0 WP 1516 00 ........ 4 WP 1913 00 ......... 0
SWP 1112 01 ........ 0 WP 1517 00 ........ 0 SWP 1913 01 ......... 5
WP 1113 00 ........ 0 WP 1518 00 ........ 0 SWP 1913 02 ......... 4
WP 1114 00 ........ 0 WP 1710 00 ........ 4 SWP 1913 03 ......... 5
WP 1210 00 ........ 0 WP 1711 00 ........ 2 SWP 1913 04 ......... 4
WP 1310 00 ........ 0 WP 1712 00 ........ 4 WP 1914 00 ......... 0
WP 1311 00 ........ 0 WP 1713 00 ........ 0 WP 1915 00 ......... *
WP 1312 00 ........ 0 WP 1714 00 ........ 0 WP 1916 00 ......... 0
WP 1313 00 ........ 4 WP 1810 00 ........ 0 WP 2110 00 ......... 0
WP 1410 00 ........ 2 WP 1811 00 ........ 0 SWP 2110 01 ......... 0
WP 1411 00 ........ 5 WP 1812 00 ........ 1 WP 2210 00 ......... 2
WP 1412 00 ........ 5 WP 1813 00 ........ 1 WP 2211 00 ......... 4
WP 1510 00 ........ 0 WP 1814 00 ........ 0 WP 2212 00 ......... 0
WP 1511 00 ........ 0 WP 1815 00 ........ 2 WP 2213 00 ......... 1
WP 1512 00 ........ 0 WP 1816 00 ........ 1 WP 2214 00 ......... 4
WP 1513 00 ........ 0 WP 1817 00 ........ 0 WP 2215 00 ......... 0
A Change 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP/SWP No. Change No. WP/SWP No. Change No.
WP 2216 00 ......... 0 WP 4023 00 ......... 0
WP 2217 00 ......... 4 WP 4024 00 ......... 0
WP 2310 00 ......... 5 WP 4025 00 ......... 0
WP 2411 00 ......... 1 WP 4026 00 ......... 0
SWP 2411 01 ......... 1 WP 4027 00 ......... 6
WP 2412 00 ......... 3 WP 4028 00 ......... 0
WP 2413 00 ......... 6
WP 2414 00 ......... 0 * - To be provided
WP 2415 00 ......... 0
WP 2510 00 ......... 6
WP 2511 00 ......... 0
WP 2610 00 ......... 6
WP 2611 00 ......... 6
WP 2612 00 ......... 0
WP 2614 00 ......... 6
WP 2710 00 ......... 6
WP 2711 00 ......... 4
WP 2810 00 ......... 0
WP 2811 00 ......... 6
WP 2812 00 ......... 0
WP 2813 00 ......... 1
WP 3010 00 ......... 3
WP 3011 00 ......... 3
WP 3012 00 ......... 5
WP 3013 00 ......... 5
WP 3014 00 ......... 5
SWP 3014 01 ......... 5
WP 3015 00 ......... 0
WP 3017 00 ......... 6
WP 4010 00 ......... 5
WP 4011 00 ......... 0
WP 4012 00 ......... 0
WP 4013 00 ......... 1
WP 4014 00 ......... 4
WP 4015 00 ......... 6
WP 4016 00 ......... 2
WP 4017 00 ......... 0
WP 4018 00 ......... 0
WP 4019 00 ......... 0
WP 4020 00 ......... 0
WP 4021 00 ......... 5
WP 4022 00 ......... 0
Change 6 B/(C Blank)
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
Table of Contents
WP/SWP Number Title
LEVEL 1 MAINTENANCE
WP 0001 00 Numerical List of Support Equipment, Consumables, and Expendables
WP 1110 00 Axial Inlet Centerbody Assembly Replacement
WP 1111 00 Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor
Replacement
WP 1112 00 Variable Inlet Guide Vane (VIGV) Actuator Replacement
SWP 1112 01 Variable Inlet Guide Vane (VIGV) Actuator Replacement with Fixed Link
WP 1113 00 Variable Inlet Guide Vane (VIGV) System Check
WP 1114 00 Forward Seal Cover Plate Replacement
WP 1210 00 Low Pressure Compressor Speed (XN2) Sensor Replacement
WP 1310 00 High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor
Replacement
WP 1311 00 Variable Bypass Valve (VBV) Actuator Replacement
WP 1312 00 Variable Bypass Valve (VBV) System Check
WP 1313 00 Bypass Valve, Bellcrank, and Actuating Ring Replacement
WP 1410 00 Variable Stator Vane (VSV) Actuator Components Replacement
WP 1411 00 Variable Stator Vane (VSV) Rigging
WP 1412 00 Variable Stator Vane (VSV) Stages 3 to 5 Bushing Replacement (High-Boss
HPC Stator Case)
WP 1510 00 Gas/Steam Fuel System Components Replacement
WP 1511 00 Dual Fuel/Water Fuel System Components Replacement
WP 1512 00 Gas/Water Fuel System Components Replacement
WP 1513 00 Liquid Fuel/Water Fuel System Components Replacement
WP 1514 00 Gas Fuel System Components Replacement
WP 1515 00 Ultraviolet Flame Sensor, L28490, Flame Sensor Sight Glass, and Flame
Sensor Bracket Replacement
SWP 1515 01 Ultraviolet Flame Sensor, L44819, Flame Sensor Sight Glass, and Flame
Sensor Bracket Replacement
WP 1516 00 Igniter Plug Replacement
WP 1517 00 High Pressure Compressor Discharge Temperature (T3) Sensor Replacement
WP 1518 00 Compressor Discharge Pressure (CDP) Bleed Air Manifold and Flange Cover
Replacement
WP 1710 00 Low Pressure Rotor Speed (XNSD) Sensor Replacement
WP 1711 00 Low Pressure Turbine Inlet Temperature (T48) Thermocouple
Replacement/Inspection
Change 6 i
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
Table of Contents (Continued)
WP/SWP Number Title
WP 1712 00Low Pressure Turbine Inlet Pressure (P48) Probe Replacement
WP 1713 00Thrust Balance Valve (TBV) Assembly Replacement
WP 1714 00Balance Piston Orifice Plate Replacement
WP 1810 00Liquid Fuel Pump Assembly, Fuel Filter Assembly, Fuel Pump Adapter, and
Quick Disconnect Adapter Replacement
WP 1811 00 Hydraulic Control Unit (HCU) and Hydraulic Filter Assembly Replacement
WP 1812 00 Variable Geometry Hydraulic Pump Replacement
WP 1813 00 Lube and Scavenge Pump Replacement
WP 1814 00 Pneumatic Starter Replacement
WP 1815 00 Hydraulic Starter and Distributor Assembly Replacement
WP 1816 00 High Pressure Compressor Speed (XN25) Sensor Replacement
WP 1817 00 Lube Resistance Temperature Detector (RTD) Replacement
WP 1910 00 Magnetic Chip Detector Replacement
WP 1911 00 Accelerometer Replacement
WP 1912 00 Liquid Fuel Manifold Temperature Sensor Replacement
WP 1913 00 External Piping, Hoses, and Electrical Harness Replacement
SWP 1913 01 Front Frame Module External Tubing, Harnesses, and Clamping
SWP 1913 02 Core Module External Tubing, Electrical Leads, and Clamping
SWP 1913 03 Low Pressure Turbine (LPT) Module External Tubing, Harnesses, and
Clamping
SWP 1913 04 Engine Assembly External Tubing, Harnesses, and Clamping
WP 1914 00 Fuel Pressurization Valve Replacement
WP 1916 00 High Pressure Compressor Water Injection (SPRINT®) Kit Removal and
Installation
LEVEL 2 MAINTENANCE
WP 2110 00 Variable Inlet Guide Vane (VIGV) Assembly Replacement
SWP 2110 01 Inlet Frame Replacement
WP 2210 00 Low Pressure Compressor (LPC) Module Replacement
WP 2211 00 Low Pressure Compressor (LPC) Stage 0 Rotor Blades Replacement
WP 2212 00 Low Pressure Compressor (LPC) Stages 0-3 Upper and Lower Stator Case
Replacement
WP 2213 00 Low Pressure Compressor (LPC) Stages 0-3 Stator Vanes Replacement
WP 2214 00 Low Pressure Compressor (LPC) Stages 1-3 Rotor Blades Replacement
WP 2215 00 Low Pressure Compressor (LPC) Aft Fan Case Replacement
WP 2216 00 Low Pressure Compressor (LPC) Stage 4 Stator Vanes Replacement
ii Change 6
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
Table of Contents (Continued)
WP/SWP Number Title
WP 2217 00 Low Pressure Compressor (LPC) Stage 4 Rotor Blades Replacement
WP 2310 00 Front Frame Air Collector Replacement
WP 2411 00 High Pressure Compressor (HPC) Upper and Lower Stator Case Replacement
SWP 2411 01 High Pressure Compressor Upper/Lower Stator Case Opening/Closing
WP 2412 00 High Pressure Compressor (HPC) Stator Vanes Replacement
WP 2413 00 High Pressure Compressor (HPC) Rotor Blades Replacement
WP 2414 00 High Pressure Compressor (HPC) Stator Outlet Guide Vanes Replacement
WP 2415 00 High Pressure Compressor (HPC) Stage 11 Check Valve - Valve Flapper
Replacement
WP 2510 00 Combustion Chamber Replacement
WP 2511 00 Stage 1 High Pressure Turbine (HPT) Nozzle Replacement
WP 2610 00 High Pressure Turbine (HPT) Module Replacement
WP 2611 00 Stage 2 High Pressure Turbine (HPT) Nozzle (On Engine) Replacement
WP 2612 00 Stage 2 High Pressure Turbine (HPT) Nozzle (Off Engine) Replacement
WP 2614 00 Stage 2 High Pressure Turbine (HPT) Rotor Blades Replacement
WP 2710 00 Low Pressure Turbine (LPT) Module Replacement
WP 2711 00 Rear Drive Adapter or Aft Seal Spacer Replacement
WP 2810 00 Radial Drive Shaft Replacement
WP 2811 00 Transfer Gearbox Assembly Replacement
WP 2812 00 Spur Gearshaft Assemblies Replacement
WP 2813 00 Accessory Gearbox Carbon Seals Replacement
PRESERVATION, HANDLING, STORAGE, AND BALANCE
WP 3010 00 Gas Turbine in Enclosure Replacement
WP 3011 00 Preservation/Depreservation
WP 3012 00 Gas Turbine Maintenance Dolly Removal and Installation
WP 3013 00 Gas Turbine/Support Pedestal Removal and Installation
WP 3014 00 Gas Turbine in Shipping Container Replacement
SWP 3014 01 Air Ride Kit Installation
WP 3015 00 Steam/Fuel Manifold Shipping Bracket Fixture Replacement
WP 3017 00 Low Pressure Turbine (LPT) Module in Shipping Container Replacement
Change 6 iii
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
Table of Contents (Continued)
WP/SWP Number Title
PERIODIC INSPECTIONS/MAINTENANCE
WP 4010 00 Gas Turbine Inlet Inspection
WP 4011 00 External Engine Cleaning
WP 4012 00 Gas Turbine External Inspection (Visual)
WP 4013 00 Gas Turbine Exhaust System Inspection
WP 4014 00 Gas Turbine Water-Wash
WP 4015 00 Borescope Inspection
WP 4016 00 Lube Oil Sampling
WP 4017 00 Lube and Scavenge Pump Chip Detector Inspection
WP 4018 00 Main Fuel Filter Replacement
WP 4019 00 Fuel Pump Filter Check
WP 4020 00 Lube and Scavenge Pump Screen Check
WP 4021 00 Variable Geometry Pump/Hydraulic Control Unit Filter Check
WP 4022 00 Pneumatic Starter Servicing
WP 4023 00 Ignition System Functional Check
WP 4024 00 Vibration Monitoring System Functional Check
WP 4025 00 Overspeed Inspection
WP 4026 00 Overtemperature Inspection
WP 4027 00 Bearing Sump Flow Tests
WP 4028 00 Variable Stator Vane Off-Schedule Inspection
iv Change 6
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 0001 00
WORK PACKAGE
TECHNICAL PROCEDURES
NUMERICAL LIST OF SUPPORT EQUIPMENT,
CONSUMABLES, AND EXPENDABLES
(LEVEL 1 AND 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 38
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 38 ...... 6
Alphabetical Index
Subject Page
Introduction................................................................................................................................. 2
List of Consumables.................................................................................................................... 23
Mechanic's Hand Tools ............................................................................................................... 2
On-Site Expendables................................................................................................................... 33
Special Tools ............................................................................................................................... 13
Change 6 1
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 0001 00
1. Introduction.
This work package contains a numerical list of special support equipment required to maintain
the LM6000 gas turbine models covered in this manual. This work package also contains a list of
recommended mechanic's hand tools, consumables, special tools, and on-site expendables to sup-
port level 1 and 2 maintenance.
2. Mechanic's Hand Tools.
See table 1.
NOTE
The following table represents a breakdown of the recommended
mechanic's hand tools needed to perform routine and corrective on-site
maintenance of the LM6000 gas turbine. The hand tools listed herein
are buyer local purchase.
Table 1. Recommended Mechanic's Hand Tools
Part Vendor
Tool Type Size Qty Number Code
Wrench, Box - 12 pt 1/4 × 5/16 2 GXDH810B A
3/8 × 7/16 2 GXDH1214A A
1/2 × 9/16 2 GXDH1618A A
Wrench, Box - 12 pt 7/32 × 1/4 2 66069 A
(thin wall) 5/16 × 3/8 2 66040 A
7/16 × 1/2 2 66042 A
Wrench, Box - 12 pt 7/16 × 1/2 1 CX1416 A
(half - moon)
Wrench, Box - 12 pt 1/4 × 5/16 2 GR810A A
(ratchet) 3/8 × 7/16 2 GR1214A A
1/2 × 9/16 2 GR1618A A
Wrench, Box - Offset 3/16 × 7/32 2 GSX67 A
1/4 × 5/16 2 GXS0810 A
3/8 × 7/16 2 GXS01214 A
1/2 × 9/16 2 GXS01618 A
5/8 × 3/4 2 GXS02024 A
Wrench, Flare Nut - 6 pt 3/8 × 7/16 2 RXF1214B A
1/2 × 9/16 RXFS1618B
5/8 × 11/16 RXFS2022A
3/4 × 13/16 RXFS246A
2 Change 6
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 0001 00
Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Wrench, Open-End 5/32 2 DS1010 A
3/16 2 DS1212 A
1/4 × 5/16 1 GV0810 A
5/16 × 3/8 1 GV01012 A
3/8 × 7/16 1 GV01214 A
7/16 × 1/2 1 GV01416 A
1/2 × 9/16 1 GV01618 A
9/16 × 5/8 1 GV01820 A
5/8 × 11/16 1 GV02022 A
5/8 × 3/4 1 GV02024 A
3/4 × 13/16 1 GV02426 A
13/16 × 7/8 1 GV02628 A
7/8 × 15/16 1 GV02830 A
1 × 1-1/16 1 GV03234 A
1-1/16 × 1-1/4 1 GV03440 A
1-1/8 × 1-3/16 1 GV03636 A
Wrench, Combination - 1/4 2 G0EX80 A
12 pt 5/16 2 G0EX100 A
11/32 2 G0EX110 A
3/8 4 G0EX120 A
7/16 2 G0EX140 A
1/2 2 G0EX160 A
9/16 2 G0EX180 A
5/8 2 G0EX200 A
11/16 1 G0EX220 A
3/4 2 G0EX240 A
13/16 1 G0EX260 A
7/8 1 G0EX280 A
15/16 1 G0EX300 A
1 1 G0EX320 A
1-1/16 1 G0EX34 A
1-1/8 1 G0EX36 A
1-3/16 1 G0EX38 A
1-1/4 1 G0EX40 A
1-5/16 1 G0EX42 A
1-3/8 1 G0EX44 A
2-1/4 1 N7829B-2 1/4 A
Change 6 3
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 0001 00
Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Wrench, Spline 1/4 × 5/16 2 GXDES810A A
3/8 × 7/16 2 GXDES1214 A
1/2 × 9/16 1 GXDES1618 A
9/16 × 5/8 1 GXDES1820A A
13/16 × 15/16 1 GXDES2630 A
Wrench, Adjustable 6″ 1 DA26 A
12″ 1 DA212 A
Socket - 12 pt 3/16 2 GTMD6 A
(1/4 drive) 3/16 Deep 2 GSTMD6 A
7/32 2 GTMD7 A
7/32 Deep 2 GSTMD7 A
1/4 2 GTMD8 A
1/4 Deep 2 GSTMD8 A
9/32 2 GTMD9 A
9/32 Deep 2 GSTMD9 A
5/16 2 GTMD10 A
5/16 Deep 2 GSTMD10 A
11/32 2 GTMD11 A
11/32 Deep 2 GSTMD11 A
3/8 2 GTMD12 A
3/8 Deep 2 GSTMD12 A
7/16 2 GTMD14 A
7/16 Deep 2 GSTMD14 A
1/2 2 GTMD16 A
1/2 Deep 2 GSTMD16 A
9/16 2 GTMD18 A
9/16 Deep 2 GSTMD18 A
Socket, Universal - 12 pt 1/4 2 GTMU81 A
(1/4 drive) 5/16 2 GTMU101 A
3/8 2 GTMU121 A
7/16 2 GTMU141 A
1/2 2 GTMU161 A
Socket - Spline 1/4 2 GTES8 A
(1/4 drive) 5/16 2 GTES10 A
5/16 Deep 2 GTEL10 A
5/16 Universal 2 GTESU10 A
4 Change 6
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WP 0001 00
Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Socket - 12 pt No. 3 Phillips 1 FP32A A
(3/8 drive) 5/16 2 GF101 A
5/16 Deep 2 GSF101 A
3/8 2 GF121 A
3/8 Square Female 2 PP412 A
3/8 Deep 2 GSF121 A
7/16 2 GF141 A
7/16 Deep 2 GSF141 A
1/2 2 GF161 A
1/2 Deep 2 GSF161 A
9/16 2 GF181 A
9/16 Deep 2 GSF181 A
5/8 2 GF201 A
5/8 Deep 2 GSF201 A
11/16 2 GF221 A
3/4 1 GF241 A
13/16 1 GF261 A
Socket, Universal - 12 pt 5/16 2 GFU10A A
(3/8 drive) 3/8 2 GFU12A A
7/16 2 GFU14A A
1/2 2 GFU16A A
9/16 2 GFU18A A
5/8 2 GFU20A A
11/16 2 GFU22A A
3/4 1 GFU24A A
Socket - Torx (1/4 drive) No. 10 1 GTTX10 A
Socket - Torx (3/8 drive) No. 30 2 GFTX30A A
No. 40 6 TX40 F
Socket - Swivel - 6 pt 3/8 2 IPF12 A
(3/8 drive) 7/16 2 IPF14 A
Change 6 5
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Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Socket - Spline 3/8 2 GFES120 A
(3/8 drive) 3/8 Deep 2 GFEL120 A
3/8 Universal 2 FESU120 A
7/16 2 GFES140 A
7/16 Deep 2 GFEL140 A
7/16 Universal 2 FESU140 A
9/16 Deep 2 GFEL180 A
9/16 Universal 2 FESU180 A
5/8 Deep 2 GFEL200 A
5/8 Universal 2 FESU200 A
Socket - 12 pt 9/16 1 GSW181 A
(1/2 drive) 5/8 1 GSW201 A
11/16 1 GSW221 A
3/4 1 GSW241 A
13/16 1 GSW261 A
7/8 1 GSW281 A
15/16 1 GSW301 A
1 1 GSW321 A
1-1/16 1 GSW341 A
1-1/8 1 GSW361 A
Socket - Spline 9/16 1 GSES181 A
(1/2 drive) 5/8 1 GSES201 A
No. 18 1 SES181 A
No. 20 1 SES201 A
No. 26 1 SES261 E
No. 30 1 SES301 C
Socket - 12 pt 1-1/16 1 GLDH342 A
(3/4 drive) 1-1/8 1 GLDH362 A
1-3/16 1 GLDH382 A
1-1/4 1 GLDH402 A
1-7/16 1 GLDH462 A
1-1/2 1 GLDH482 A
1-5/8 1 GLDH522 A
1-3/4 1 GLDH562 A
2 1 LDH642 A
2-1/4 1 GLDH722 A
2-3/8 1 LDH762 A
6 Change 6
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Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Socket - 6 pt 2-5/8 1 L843 A
(1-inch drive)
Crowsfoot - 12 pt 1/4 1 TMRX8 A
(1/4 drive) 5/16 1 TMRX10 A
3/8 1 AN8508-6A A
7/16 1 AN8508-7A A
1/2 1 AN8508-8A A
9/16 1 AN8508-9A A
Crowsfoot - 12 pt 5/8 1 GAN8508-10A A
(3/8 drive) 11/16 1 GAN8508-11A A
3/4 1 GAN8508-12A A
13/16 1 GAN8508-13A A
7/8 1 GAN8508-14A A
15/16 1 GAN8508-15A A
1 1 GAN8508-16A A
1-1/16 1 GAN8508-17A A
Crowsfoot - Open End 3/8 2 GFC012 A
(3/8 drive)
Crowsfoot - Flare Nut - 9/16 1 FRH180S A
6 pt (3/8 drive) 5/8 1 FRH200S A
11/16 1 FRH220S A
3/4 1 FRH240S A
13/16 1 FRH260S A
7/8 1 FRH280S A
15/16 1 FRH300S A
1 1 FRH320S A
Change 6 7
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 0001 00
Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Crowsfoot - 12 pt 1-1/8 1 GAN8508-18A A
(1/2 drive) 1-3/16 1 GAN8508-19A A
1-1/4 1 GAN8508-20A A
1-5/16 1 GAN8508-21A A
1-3/8 1 GAN8508-22A A
1-7/16 1 GAN8508-23A A
1-1/2 1 GAN8508-24A A
1-9/16 1 GAN8508-25A A
1-5/8 1 GAN8508-26A A
1-11/16 1 GAN8508-27A A
1-3/4 1 GAN8508-28A A
1-13/16 1 GAN8508-29A A
1-7/8 1 GAN8508-30A A
1-15/16 1 GAN8508-31A A
2 1 GAN8508-32A A
2-1/16 1 GAN8508-33A A
2-1/8 1 GAN8508-34A A
2-1/4 1 GAN8508-36A A
2-1/2 1 GAN8508-40A A
Crowsfoot - Open-End 1-1/16 1 GSC034 A
(1/2 drive) 1-1/4 1 GSC040 A
1-1/2 1 GSC048 A
1-3/4 1 GSC056 A
2 1 GSC064 A
Speed Handle 1/4 Drive 2 GTMS4D A
1/4 Drive 2 GTMS4E A
3/8 Drive 2 GF4LA A
1/2 Drive 1 KB4 A
Ratchet Handle 1/4 Drive 2 GM70T A
1/4 Drive 5″ Long 2 TM75A A
3/8 Drive 2 GFL720A A
3/8 Drive 7″ Long 2 F720B A
1/2 Drive 10″ Long 2 GS710A A
3/4 Drive 20″ Long 1 GL72H A
3/4 Drive 24″ Long 1 GL72TH A
Ratchet Head 3/4 Drive 1 GL72T A
8 Change 6
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Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Breaking Bar 1/4 drive 1 GTM10F A
3/8 Drive 1 GF10M A
1/2 Drive 1 GSN18A A
3/4 Drive 36″ Long 1 L112EL A
Extension (1/4 drive) 2″ 1 GTMX2 A
4″ Wobble 1 GTMXW4 A
6″ 1 GTMX60 A
6″ Wobble 1 GTMXW60 A
10″ 1 GTMX100 A
14″ 1 GTMX140 A
Extension (3/8 drive) 3″ Wobble 1 GFXW3 A
6″ 1 GFX6 A
12″ 1 GFX11A A
Extension (1/2 drive) 5″ 1 GS5 A
10″ 1 GS10 A
Extension (3/4 drive) 3″ 1 GL32 A
8″ 1 GL62 A
8″ 1 GS62 A
16″ 1 GS122 A
Adapter, Torque 1/4F × 3/8M 1 GTA3 A
3/8F × 1/4M 1 GTM1 A
3/8F × 1/2M 1 GAF2 A
1/2F × 3/8M 1 GAX1 A
1/2F × 3/4M 1 GLA12A A
3/4F × 1/2M 1 GLA62 A
1F × 3/4M 1 GLA124A A
Adapter, Torque - 12 pt 1/4 2 GFRDH081 A
(3/8 drive) (thin wall) 5/16 2 GFRDH101 A
3/8 2 GFRDH121 A
7/16 2 GFRDH141 A
1/2 2 GFRDH161 A
9/16 2 GFRDH181 A
Change 6 9
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Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Adapter, Torque - Spline 5/16 2 GFRES10 A
(3/8 drive) 3/8 2 GFRES12 A
7/16 2 GFRES14 A
9/16 2 GFRES16 A
5/8 2 GFRES18 A
5/16 2 GFRES10 A
3/8 2 GFRES12 A
7/16 2 GFRES14 A
9/16 2 GFRES16 A
5/8 2 GFRES18 A
Universal Joint 1/4 Drive 1 GTMU8 A
3/8 Drive 1 GFU8A A
1/2 Drive 1 GU8 A
Torque Wrench 1/4 Drive 30-200 lb in 1 AJR117E A
3/8 Drive 150-1000 lb in 1 QJR248E A
1/2 Drive 30-250 lb ft 1 A
3/4 Drive 0-600 lb ft 1 QJR3250A A
1 TEC602FUA A
Strap Wrench 1-6″ 1 A91C A
1-3/4 × 29-1/4″ 1 No. 5 D
Allen Wrench Set 3/64 - 3/8 2 AW1013AK A
0.028 - 3/8 2 GAW1015AK A
Hammer
- Compothene 24 oz 1 BC1A A
- Plastic Tip 16 oz 1 BE116 A
- Soft-Faced 13″ 1 BH232-2 A
- Ball Peen 16 oz 1 BPN16B A
32 oz 1 BPN32A A
Punch
- Nylon 3/4″ dia × 12″ long 1 A
- Bronze 3/4″ dia × 12″ long 1 PPC1002 A
- Pin Set 1/4″ dia 1 PPC108A A
- Pin Set 5/16″ dia 1 PPC110A A
- Starter 1/4″ dia 1 PPC208A A
- Tapered Set 1 PPC905A A
10 Change 6
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Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Screwdriver 4″ × 1/4″ Blade Tip
- Common 6″ 2 GSSD44 A
6″ × 5/16″ Blade Tip 2 SDD6 A
8″ 2 SDD46 A
8″ × 3/8″ Blade Tip 2 SDD8 A
Pocket Size 2 SDD48 A
- Phillips No. 1 6″ 2 SDDP204 A
6″ 2 SDDP61 A
- Phillips No. 2 No. 30 2 SDDP62 A
- Torx Tip 2 STDTX430 C
- Magnetic Set 1 SSDM40B A
- Miniature Set 1 CM6551 A
Pliers
- Bent Needle Nose 10 1/2″ 1 497ACP B
- Safety-Wire Twister 2 GA311C A
- Wire Twister/Cutter 5-1/16″ 2 PR311 A
- Diagonal Cutting 2 86ACP A
2 E710CG A
- Retaining Ring Set 1 PR36 A
- Electrical Connector, PWC50 A
Vinyl/Jaws
- Needle Nose 1 196ACP A
1 95ACP A
- Flat Nose 6″ 1 61CP B
- Standard 1 46C B
- Adjustable Joint 12″ 1 91CP A
- Water Pump HL112P A
- Line Clamp 1 SWE82 A
Measuring 0-6″
- Micrometer, Depth 0-1″ 1 445AZ6RL C
- Micrometer, Outside 1 230RL C
Depth Gage 0-18″
- Vernier Depth 1 448-18 C
Gage 6″
- Steel Rule 6″ 1 622R A
- Pocket Rule 26 blade 1 PMF131 A
- Feeler Gage 1 FB335 A
Change 6 11
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Volume II GE Industrial AeroDerivative Gas Turbines
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Table 1. Recommended Mechanic's Hand Tools (Continued)
Part Vendor
Tool Type Size Qty Number Code
Inspection Mirror 1-1/4″ dia 1 CF143A A
2-1/4″ dia 1 GA295 A
Oval Pocket Mirror 1 CF157A A
Mechanical Fingers 17-3/4″ 1 GA265A A
Magnetic Pickup 17-27″ 1 PT30B A
Pry Bar 16″ 1 1650 A
Pinch Bar 16″ 1 1658B A
Scriber 1 PTS5 A
Flashlight 2 Cell 1 ECF35 A
Drop Light 2 EC691 A
India Stone - Fine 1 FF156 B
1 FF214 B
1 FF24 B
Parallel Bars 6″ 1 - -
12″ 1 - -
Tool Box 33 × 18 × 13 1 KR547B A
Vendor Code: A = Snap-On Tools
B = Utica/Triangle
C = Starrett
D = Ridgid
E = Cole Manufacturing
F = Apex
12 Change 6
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3. Special Tools.
Refer to table 2.
NOTE
• For GE designed tooling, equivalent tooling may be furnished by
the Original Equipment Manufacturer (OEM).
• Consult GE for current tool configuration prior to ordering.
Table 2. Special Tools
Part No. Nomenclature Category Work Package
00202050000 Kit, Air Ride – 3014 01
106C7154P04-P07 Container, Shipping and Storage - Gas – 3014 00
Turbine 3014 01
106C7158P02-P04 Container, Shipping - LPT Alternate 3017 00
106C7158P05 Container, Shipping - LPT Recommended 3017 00
1C3569G2 Pressurizer, Hydraulic Unit Recommended 3011 00
1C3569G3 Hydraulic Actuator Unit Recommended 1112 00
1113 00
1311 00
1312 00
1313 00
1410 00
1411 00
2110 00
3011 00
1C5654G03 Jack, Lowering - Engine Components Optional 2310 00
2811 00
1C6119G01 Guide, Expandable Bushing Recommended 2811 00
1C6361G01 Tool Set, Radial Drive Shaft Recommended 2810 00
1C6804G04 Tool Set, Jackscrew Recommended 2511 00
2710 00
1C6872G01 Fixture, Instal/Removal - Access Gear- Recommended 2811 00
box, Horiz
1C6892G01 Pusher, Bolt - Front Frame/TGB Fwd Recommended 2811 00
MTG Bracket
1C6986G01 Tool Set, Assy/Disassy - Gearbox Recommended 2812 00
1C8182G01 Fixture Set, Mating Seal Removal Recommended 2813 00
1C8208G02 Spline Adapter, Manual or Front Drive Recommended 3011 00
Pad 4015 00
1C9052G01 Dolly, LPC Rotor and Stator - Vertical Optional 2210 00
Change 6 13
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WP 0001 00
Table 2. Special Tools (Continued)
Part No. Nomenclature Category Work Package
1C9053G01 Fixture, Lift and Turn - LPC Rotor and Recommended 2210 00
Stator
1C9054G02 Fixture, Lift - LPC Rotor and Stator, Recommended 2210 00
Horiz
1C9116G01 Fixture, Lift - LPC Rotor and Stator, Recommended 2210 00
Fwd
1C9150G02 Tool Set, Jackscrew Recommended 1412 00
2210 00
2412 00
2414 00
2511 00
2710 00
1C9300G01 Fixture, Lift - Air Collector Optional 2310 00
1C9309G03 Fixture, Torque - LPT Shaft Coupling – 2711 00
Nut
1C9316G02 Adapter, Sleeve - LPT Rotor Shaft Recommended 2710 00
1C9317G01 Adapter, Support/Lift - LPC Recommended 2210 00
1C9327G03 Puller, LPT Module - Mid-Shaft Recommended 2710 00
2711 00
1C9328G01 Strongback, Lift, Turn and Restrain - – 2711 00
LPT Module
1C9329G02 Puller Plate, Aft Drive Adapter – 2711 00
1C9336G01 Fixture Assembly, Install/Remove - Aft Recommended 2710 00
Drive Shaft Nut 2711 00
Deleted
1C9338G02 Fixture, Forward Restrain - LPT Recommended 2710 00
Rotor/Stator 3017 00
1C9353G02 Tool Set, Rigging, VBV Doors Recommended 1312 00
1313 00
1C9354G03 Dolly Assembly, Gas Turbine Change- Recommended 3014 00
out
1C9358G02 Fixture Assy, Lift - HPT Rotor Horizon- Alternate 2611 00
tal
1C9358G03 Fixture Assy, Lift - HPT Rotor Horizon- Recommended 2610 00
tal 2611 00
1C9359G02 Rigging Set, VIGV Recommended 1113 00
1C9362G01 Adapter, Lift - Combustor, Stage 1 or 2 Recommended 2510 00
HPT Nozzle
1C9362G02 Adapter, Lift - Combustor, Stage 1 or 2 Recommended 2511 00
HPT Nozzle
14 Change 6
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WP 0001 00
Table 2. Special Tools (Continued)
Part No. Nomenclature Category Work Package
1C9365G01 Protractor Assy, Electronic, Portable - Alternate 1411 00
VSV
1C9371G02 Ring Assembly, VIGV Case Support Recommended 3012 00
3013 00
1C9372G06/G07 Maintenance Dolly, External Engine Recommended 3012 00
1C9375G03 Adapter Set, Air Collector Support Recommended 3012 00
3013 00
3014 00
1C9376G01/G02 Jack Assembly, CRF Support Recommended 2411 01
Deleted
1C9377G01 Adapter Set, LPC Support Recommended 3012 00
3013 00
1C9378G03 Adapter Assy, Engine External Maint Recommended 3012 00
Dolly
1C9381G01 Fixture Assy, Shipping Bracket - Recommended 1510 00
Steam/Fuel Manifold 1511 00
1512 00
1514 00
3015 00
1C9381G02 Fixture Assy, Shipping Bracket - Recommended 3015 00
Steam/Fuel Manifold
1C9384G03/G04 Support Pedestals, Storage and Mainte- Alternate 3013 00
nance
1C9385G01 Fixture, LPC Rotor and Stator Support Recommended 2210 00
1C9390G01 Fixture Assembly, Lift & Turn - VIGV Recommended 2110 00
2110 01
1C9393G01 Adapter Set, Pressure Test/Rig - VIGV, Recommended 1112 00
VBV, VSV 1113 00
1311 00
1312 00
1313 00
1410 00
1411 00
2110 00
1C9397G01 Holder, Shim - HPT Pressure Tube Recommended 2610 00
Adapter
1C9400G01 Fixture Set, Raise & Hinge - Upper – 2411 01
Compressor Case
1C9403G01 Fixture, Check VSV/VIGV Actuator – 1112 00
1410 00
Deleted
Change 6 15
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WP 0001 00
Table 2. Special Tools (Continued)
Part No. Nomenclature Category Work Package
1C9408G02 Fixture Set, VSV Torque Measuring Recommended 1412 00
2412 00
1C9412P01 Fixture, Retention, HPC Variable Stator – 1412 00
Vane
1C9413G01 Fixture, HPC Dummy Stator Case Optional 2411 00
1C9414G01 Retainer, HPC Bottom Stator Case, Optional 2411 00
6-12 Vanes
1C9417G01 Stand - HPT Rotor Stage 2 Nozzle - – 2610 00
Horiz
1C9419G01 Jack Assembly, CRF Support – 2411 00
1C9428G01 Wrench, VSV Locknut Torque Break – 1412 00
2412 00
1C9444G01 Fixture, Clamp - HPT Rotor Disks Recommended 2614 00
1C9448G01 Jack Assembly, Support - Compressor Recommended 3012 00
Rear Frame
1C9448G02 Jack Assembly, Support - Compressor Recommended 3013 00
Rear Frame
1C9459P01 Guide Tube, Borescope - HPT Diffuser Recommended 4015 00
1C9602G01 Fixture, Lift - LPC Case, Stages 0-3 – 2212 00
1C9608G02 Fixture, Install/Remove - HP Turbine – 2610 00
Module
1C9609G01 Assembly, Rear Drive Adapter – 2710 00
2711 00
1C9610G01 Pilot, LP Mid-Shaft - Aft – 2610 00
2710 00
1C9613G02 Strongback, Lift, Turn and Restrain - – 2710 00
LPT Module 2711 00
3017 00
1C9616G01 Fixture, Seat Check - Coupling Nut, – 2710 00
Shaft, LPT Rotor
1C9617G01 Fixture, Start - LPT Coupling Nut – 2710 00
1C9618G01 Fixture, Install/Remove - Retainer Ring – 2710 00
LPT/Mid-Shaft
1C9619G02 Fixture, Torque - LPT Shaft Coupling – 2710 00
Nut 2711 00
1C9620G01 Gage Inspection - Fan Shaft to HPT – 2710 00
Stator Case
1C9622G01 Collar Mid-Shaft, Centering and – 2710 00
Support
16 Change 6
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WP 0001 00
Table 2. Special Tools (Continued)
Part No. Nomenclature Category Work Package
1C9625G01 Fixture Assembly, Horizontal Lift Recommended 3010 00
3012 00
3013 00
3014 00
1C9626G01 Torque Adapter, Pressure Tube/Cou- – 2610 00
pling Nut-HPT Rotor
1C9627G01 Fixture, Adjustable C.G. Horizontal Lift – 2710 00
- Heavy Purpose 3017 00
1C9632G01 Dolly, Storage, LPT Module – 2710 00
3017 00
1C9642G01 Lift and Remove Fixture, Aft Seal – 2711 00
Spacer
1C9643G01 Lift and Remove Fixture, Aft Seal – 2711 00
Spacer
1C9650G01 Puller, High Force - LPT Module Mid Recommended 2710 00
Shaft (Alternate for 1C9327G03)
1C9651G01 Pusher, LPT Shaft Bushing – 2710 00
2C14025G05 Pusher Set, Races/Seals - HPTR Stage 1 – 2610 00
Deleted
Deleted
2C14094G06 Fixture, Seat Check - No. 4B Bearing Recommended 2610 00
and Seal
2C14131G02 Fixture, Seat Check - HPT Rotor Recommended 2610 00
2C14193G03 Stand, Shipping/Storage - HPT Module Optional 2610 00
2612 00
2C14198G02 Removal Tool, HPC Stage 1 Blade Recommended 2413 00
Retainer
2C14199G10 Fixture, Install/Remove - HPT Module Recommended 2610 00
Assembly
2C14219G01 Adapter, Lift - Combustor, Stage 1 or 2 Alternate 2510 00
HPT Nozzle
2C14220G01 Fixture Assy, Lift - HPTR Horizontal Alternate 2610 00
2C14290G01 Adapter, Torque – 2511 00
2C14664G01 Wrench Set, No. 5R Bearing Inner Race Recommended 2610 00
Nut
Deleted
2C14679P01 Sleeve, Retaining - No. 4B Bearing Recommended 2610 00
Stack-Up
2C14684G02 Removal Tool, Vane Spring Retainers – 2412 00
Change 6 17
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Table 2. Special Tools (Continued)
Part No. Nomenclature Category Work Package
2C14688G05 Puller, Races and Seals - HPT Rotor Recommended 2610 00
Stage 1
2C14689G01 Adapter, Lift - Install/Remove Recommended 2510 00
2C14691G01 Fixture, Install/Remove - Combustor Recommended 2510 00
2C14693G01 Guide Clamps Recommended 2710 00
2C14695G01 Fixture, Lift - Stage 1 HPT Nozzle Recommended 2511 00
Assembly
2C14699G02 Fixture, Lift - Compressor Stator Case, – 2411 00
Upper
2C14703G01 Adapter, Lift - HPT Nozzle, Stage 2 Recommended 2611 00
2612 00
2C14754G01 Fixturing Clamps – 1913 03
2C14764G05 Drive Motor, Electric (115 VAC 50/60 Optional 3011 00
and 400 Hz, 28 VDC) 4015 00
2C14764G06 Drive Motor, Electric (220 VAC 50 Hz Optional 3011 00
and 28 VDC) 4015 00
2C14779G02 Tool Set, Alignment - Compressor Optional 2411 00
Horizontal Flange 2411 01
2C14784G01 Fixture, Remove - HPT Rotor Aft Outer Optional 2610 00
Air Seal
2C14785G02 Fixture, Pull - HPT Rotor Aft Air Seals Recommended 2610 00
2C14796G02 Gage, Length - HPT Rotor, Stage 2 Recommended 2614 00
Blade
2C6018G01 Tool Set, Holding VSV Recommended 2412 00
2C6019G03 Driver Set, Compressor Stator Vane Optional 2412 00
2C6171G02 Holder Set, VSV Optional 2412 00
2C6259G05 Fixture, Holding - Variable Stator Arms, Optional 2411 00
Stages 3-6 2411 01
2C6348P02 Guide Pin - Fan Rotor Installation Recommended 2210 00
2C6395G05 Fuel System Preservation Pump – 3011 00
2C6599G01 Prebend Tool, HPC Stage 1 Blade Recommended 2413 00
Retainer
2C6600G03 Seating Tool, HPC Stage 1 Blade Recommended 2413 00
Retainer
2C6613G01 Gage, Immersion Depth - Igniter Plug Recommended 1516 00
2510 00
2C6647G01 Wrench, VSV Spacer Spanner – 1412 00
18 Change 6
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 0001 00
Table 2. Special Tools (Continued)
Part No. Nomenclature Category Work Package
2C6883G01 Fixture, Mounting/Drilling, Fuel – 1510 00
Nozzle 1511 00
1512 00
1513 00
1514 00
2C6925G03 Gage Set, VSV Clevis Recommended 1411 00
2C6948P06 Flex Borescope Guide Tube Recommended 4015 00
2C6962G05 Gage, Sight - VSV Actuation Arms – 4028 00
2C6966G07 Gage, Sight - VSV Actuation Arms – 4028 00
2C6967G06 Stop Install Tool, HPC Stage 2 Blade Recommended 2413 00
Retainer
2C6968G02 Stop Removal Tool, HPC Stage 2 Blade Recommended 2413 00
Retainer
2C8016G02 Gage, Sight - VSV Stage 5 Actuation – 4028 00
Arms
9429M49G01 Fixture, Puller - Exhaust Gas – 1711 00
Temperature Probe
9446M61G02 (or Program, Balance - Blade Replacement – 2211 00
latest CD-Rom 2214 00
version) 2217 00
2413 00
2614 00
9453M62G01 Air Flow Tester, Portable Lube System – 4027 00
AN919-10 Reducer – 3011 00
AN919-6 Reducer – 3011 00
Deleted
Everest XLG3 Borescope Equipment (6 mm [or less] – 4015 00
VideoProbe diameter probe) with Optical
Measurement Capability
Local Mfg. Bushing Rework Tool – 2412 00
Local Mfg. Depth Gage – 2412 00
Local Mfg. Drilling Jig – 2412 00
Local Mfg. Fixture, Holding – 2413 00
Local Mfg. Handle, Stator Vane Tang Extension – 1412 00
Local Mfg. Removal Kit, HPC Rotor Locking Lugs – 2413 00
(Contact Customer Support Manager
for copy of drawing 4013408)
Local Purchase 3374A21 Transfer Punch – 2412 00
(Ref. McMaster)
Local Purchase 7 mm or 9/32 inch Diameter Drill – 2412 00
(bushing rework)
Change 6 19
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Table 2. Special Tools (Continued)
Part No. Nomenclature Category Work Package
Local Purchase 7/32 inch Diameter Drill (case rework) – 2412 00
Local Purchase 8492A102 Drill Guide (Ref. McMaster) – 2412 00
Local Purchase 8492A176 Drill Guide (Ref. McMaster) – 2412 00
Local Purchase Adjustable Drill Stop (7/32 Inch – 2412 00
Diameter)
Local Purchase Bottle Jack – 1313 00
2310 00
Local Purchase Depth Gage, Vernier – 2711 00
Local Purchase Depth Micrometer – 2711 00
Local Purchase Driver, No. 10 Torque-Set Recommended 1110 00
Local Purchase Dynamometer, 10,000 lb (4,536 kg) – 2710 00
Capacity
Local Purchase Grinding Die Pneumatic Grinder – 1916 00
Local Purchase Hammer, Soft-faced – 1815 00
Local Purchase Heat Gun – 1711 00
2510 00
2511 00
2711 00
Local Purchase HSS 0.250-28 UNJF-3B Tap Set – 2412 00
(Taper, Plug and Bottoming Taps)
Local Purchase Lifteye (0.500-13UNC-2B Thread) – 2510 00
2710 00
Local Purchase Load Cell, 10,000 lb (4,536 kg) – 2710 00
Capacity (Alternate to Dynamometer)
Local Purchase Lubricating Stand – 3011 00
Local Purchase Megohmmeter – 4024 00
Local Purchase Pliers, Soft Jaw – 1412 00
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Table 2. Special Tools (Continued)
Part No. Nomenclature Category Work Package
Local Purchase Pliers, Teflon-Jawed – 1111 00
1112 00
1112 01
1210 00
1310 00
1311 00
1511 00
1512 00
1513 00
1517 00
1710 00
1713 00
1811 00
1813 00
1814 00
1816 00
1817 00
1910 00
1911 00
1912 00
1913 01
1913 02
1913 03
1913 04
2110 00
2212 00
Local Purchase Pull Scale, Calibrated 0-50 lb – 1412 00
2412 00
Local Purchase Rivet Squeezer – 2511 00
Local Purchase Slave Nuts (Qty 12, 0.375-24 thread) – 2511 00
Local Purchase Sling, General Purpose – 1510 00
1511 00
1512 00
1514 00
Local Purchase Torque Wrench, Advanced Hydraulics, – 2711 00
Model AH-1043
Local Purchase Ultrasonic Cleaner – 4019 00
Local Purchase Wrench, Strap – 4018 00
Locally Fabricated Guide Pins (Qty 3, 0.190-32 by 1.0 inch – 2813 00
bolt with head removed)
MS51525B6-8S Reducer – 3011 00
MS51525B8-10S Reducer – 3011 00
Change 6 21
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Table 2. Special Tools (Continued)
Part No. Nomenclature Category Work Package
MS51525B8-12S Reducer – 3011 00
MS51525B8S Union – 3011 00
MS51532B10S Cap – 3011 00
MS51532B6S Cap – 3011 00
MSE-28 Wrench Recommended 2413 00
MSE-53 Sling, Lift – 1313 00
2612 00
3012 00
3013 00
P802 (ENERPAC) Pump, Hand Recommended 2710 00
Sweeney Model 18932 Drive Motor, Pneumatic – 3011 00
Sweeney Model 8100 Torque Multiplier Alternate 2610 00
2710 00
2711 00
Sweeney Model 8102 Torque Multiplier Alternate 2610 00
Sweeney Model 8112 Torque Multiplier Alternate 2610 00
2710 00
2711 00
Sweeney Model 8112B Torque Multiplier Recommended 2610 00
2710 00
2711 00
Sweeney Model 8200 Torque Multiplier Recommended 2610 00
2710 00
2711 00
Sweeney Model 8202A Torque Multiplier Recommended 2610 00
XL Go VideoProbe Borescope Equipment (6 mm [or less] – 4015 00
diameter probe) with Optical
Measurement Capability
22 Change 6
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4. List of Consumables.
Refer to table 3 for a list of consumables recommended to support on–site level 1 and 2
corrective maintenance tasks. For consumable materials required to support an individual
maintenance task, refer to the specific work package covering that task.
Table 3. Consumable Materials
Nomenclature Specification Manufacturer Work Package
Adhesive Scotch Grip 77 3M Company 2611 00
2612 00
2613 00
2614 00
Anti-Seize Compound Milk-of-Magnesia Local Purchase 1412 00
(Unflavored)
ARDROX 6322 N/A Local Purchase 4011 00
4014 00
B&B 3100 N/A B&B Tritech, Inc. 4011 00
P.O. Box 660-776 4014 00
Miami, FL 33266-0776
USA
Barrier Paper, Kraft Grade A, Type II, Ludlow Corp. 3011 00
Class II Packaging Div.
111 Mosher St.
Holyoke, MA 01040
USA
Beeswax N/A Local Purchase 2510 00
Corrosion Preventive Oil MIL-C-16173 Ashland Oil Corp. 4019 00
P.O. Box 1400
Lexington, KY 40509
USA
Atochem North America
Turco Products Division
P.O. Box 195
Highway 95 West
Marion, OH 43302
USA
Corrosion Preventive Oil MIL-C-6529 Bray Oil Co. 4019 00
Div. of Burmah Castrol
16715 Von Karmen Ave.
Irvine, CA 92714
USA
Royal Lubricants Co.
72 Eagle Rock Ave.
East Hanover, NJ 07936
USA
Change 6 23
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Table 3. Consumable Materials (Continued)
Nomenclature Specification Manufacturer Work Package
Corrosion Preventive Oil MIL-L-6085 Local Purchase 4019 00
4021 00
Desiccant MIL-D-3464 Local Purchase 3014 00
3017 00
Desiccant MIL-P-116 Local Purchase 3011 00
Dry Cleaning Solvent Fed Spec P-D-680, Local Purchase 4017 00
Type II 4019 00
4021 00
Dry Film Lubricant GE Spec Sandstrom Products Co. 2710 00
A50TF192, CL- 224 Main St.
B Port Byron, IL 61275
USA
Dry Ice Fed Spec BB-C- Local Purchase 2611 00
104 2612 00
2613 00
2614 00
Epoxy Paint MIL-C-22750, Local Purchase 1916 00
Color 26307
European Loctite 275 MIL-S-46163A, Local Purchase 1313 00
Type I, Grade A
Fuel System Preservation MIL-L-6081C, Bray Oil Company 3011 00
Oil Grade 1010 Div. of Burmah Castrol
16715 Von Karmen Ave.
Suite 230
Irvine, CA 92714
USA
Delta Petroleum Inc.
P.O. Box 10397
Jefferson, LA 70181
USA
24 Change 6
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Table 3. Consumable Materials (Continued)
Nomenclature Specification Manufacturer Work Package
Isopropyl Alcohol Fed Spec TT-I-735 Local Purchase 1410 00
1412 00
1711 00
1712 00
1816 00
2213 00
2216 00
2411 00
2411 01
2412 00
2413 00
2415 00
2610 00
2710 00
2711 00
4011 00
4014 00
4019 00
4020 00
Loctite 271 MIL-S-46163A, 1313 00
Type I, Grade A
Lubricating Oil MIL-PRF-23699F Local Purchase 1112 01
(C/I) 1311 00
1312 00
1410 00
1811 00
1812 00
1813 00
1814 00
1815 00
1817 00
1910 00
1913 01
1913 04
1916 00
2110 00
2210 00
2510 00
2511 00
2710 00
2810 00
2812 00
Change 6 25
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Table 3. Consumable Materials (Continued)
Nomenclature Specification Manufacturer Work Package
Lubricating Oil MIL-PRF-23699F Local Purchase 2813 00
(Cont.) (C/I) 3011 00
4017 00
4019 00
4020 00
Marking Pen Dykem (Water Sanford Corp. 4015 00
Based White or 2740 Washington Blvd.
Yellow) Bellwood, IL 60104
USA
Marking Pen Sharpie T.E.C. Sanford Corp. 1313 00
(Black or Blue) 2740 Washington Blvd. 1410 00
Bellwood, IL 60104 1411 00
USA 1412 00
2110 00
2110 01
2210 00
2211 00
2212 00
2214 00
2217 00
2310 00
2411 00
2411 01
2412 00
2413 00
2510 00
2511 00
2610 00
2611 00
2612 00
2613 00
2614 00
2710 00
2711 00
2812 00
3010 00
Marking Pen Sharpie T.E.C. 4015 00
(Water Based
White or Yellow)
26 Change 6
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Table 3. Consumable Materials (Continued)
Nomenclature Specification Manufacturer Work Package
Molybdenum Disulfide MIL-L-25681 Royal Lubricant Co., Inc. 1210 00
Lubricant P.O. Box 298 1311 00
Royco 81MS East Hanover, NJ 07936 1312 00
USA 1313 00
1913 01
1916 00
2210 00
2211 00
2214 00
2217 00
2310 00
2413 00
2811 00
Monopropylene Glycol AMS 1424 Local Purchase 4011 00
4014 00
Penetrating Oil GE Spec Radiator Specialty Co. 1714 00
A50TF54, CL-A P.O. Box 34689 1913 03
1900 Wilkerson Blvd. 2214 00
Charlotte, NC 28234 2217 00
USA 2413 00
2610 00
2611 00
2612 00
2613 00
2614 00
2710 00
Petrolatum Fed Spec VV-P-236 Local Purchase 1310 00
1710 00
1810 00
1812 00
1914 00
2210 00
2413 00
2511 00
2610 00
2812 00
2813 00
RMC Turbine/Engine N/A Local Purchase 4011 00
Cleaner (Rivenaes) 4014 00
Rochem FYREWASH N/A Local Purchase 4011 00
4014 00
Change 6 27
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Table 3. Consumable Materials (Continued)
Nomenclature Specification Manufacturer Work Package
Rust Preventative GE Spec D50TF6 Bay Oil Company 3011 00
Concentrate or Brayco 599 Div. of Burmah Castrol
16715 Von Karmen Ave.
Suite 230
Irvine, CA 92714
USA
Safety Cable 736L680G01 Bergen Cable Technolo- 1112 00
gies, Inc. 1310 00
Gregg St. 1311 00
P.O. Box 1300 1313 00
Lodi, NJ 07644 1410 00
USA 1411 00
Daniels Mfg. Corp. 1412 00
526 Thorpe Road 1510 00
Orlando, FL 32824 1511 00
USA 1512 00
1513 00
1514 00
1515 00
1516 00
1517 00
1710 00
1712 00
1816 00
1910 00
1911 00
1913 01
1913 02
1913 03
1913 04
1916 00
2310 00
2411 00
2411 01
2412 00
2510 00
2610 00
2710 00
28 Change 6
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Table 3. Consumable Materials (Continued)
Nomenclature Specification Manufacturer Work Package
Safety Cable 736L680G01 Bergen Cable Technolo- 2711 00
(Cont.) gies, Inc. 2810 00
Gregg St. 2812 00
P.O. Box 1300 3010 00
Lodi, NJ 07644 3011 00
USA 4015 00
Daniels Mfg. Corp. 4020 00
526 Thorpe Road 4021 00
Orlando, FL 32824 4023 00
USA
Safety Wire (0.020 inch) R297P02 Adams Industries 1412 00
Box 291 1913 01
Windsor Locks, CT 06096 1913 02
USA 3010 00
Safety Wire (0.032 inch) R297P04 Adams Industries 1112 00
Box 291 1112 01
Windsor Locks, CT 06096 1310 00
USA 1311 00
1313 00
1410 00
1411 00
1510 00
1511 00
1512 00
1513 00
1514 00
1515 00
1516 00
1517 00
1710 00
1712 00
1816 00
1910 00
1911 00
1913 01
1913 02
1913 03
1913 04
1914 00
1916 00
2310 00
2411 00
Change 6 29
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Table 3. Consumable Materials (Continued)
Nomenclature Specification Manufacturer Work Package
Safety Wire (0.032 inch) R297P04 Adams Industries 2411 01
(Cont.) Box 291 2412 00
Windsor Locks, CT 06096 2510 00
USA 2610 00
2710 00
2711 00
2810 00
2812 00
3010 00
3011 00
4015 00
4020 00
4021 00
4023 00
Sharpening Stone Fed Spec Local Purchase 2211 00
SS-S-736C 2214 00
2412 00
Silicone Rubber Adhesive GE Spec A15F6B6 GE Company Silicone 1410 00
(RTV 106) Products Division 1816 00
260 Hudson River Rd. 2213 00
Waterford, NY 12188 2216 00
USA 2412 00
Dow Corning Corp 2413 00
P.O. Box 994 4012 00
Midland, MI 48686-0994
USA
Silicone Tape MIL-I-46852 Local Purchase 1913 01
1913 02
1913 03
1913 04
Soap Solution N/A Local Purchase 1112 00
1311 00
1410 00
2110 00
Sodium Dichromate N/A Local Purchase 4019 00
Crystals
(Commercial Grade,
99.5% min)
Solid Film Lubricant GE Spec – 2710 00
A50TF147,
CL-A
30 Change 6
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Table 3. Consumable Materials (Continued)
Nomenclature Specification Manufacturer Work Package
Spray Lubricant GE Spec. Sandstorm Products Co. 1313 00
A50TF192, 224 Main St.
CL-B Port Byron, IL 61275
USA
Sulfuric Acid Fed Spec O-S-809 Local Purchase 4019 00
(Technical Grade,
66° Baume)
Tape N/A Local Purchase 2413 00
2611 00
4015 00
Tapping Fluid N/A Trim Tap NC (Masters 2412 00
Chemical Co.)
Thread Lubricant GE Spec Acheson Colloids Co. 1112 00
A50TF201 6315 Warren-Sharon Rd. 1113 00
P.O. Box 120 1114 00
Brookfield, OH 44403 1410 00
USA 1516 00
1711 00
1713 00
1714 00
2110 00
2110 01
2210 00
2211 00
2212 00
2215 00
2511 00
2610 00
2611 00
2612 00
2613 00
2614 00
2711 00
3010 00
3015 00
Change 6 31
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 0001 00
Table 3. Consumable Materials (Continued)
Nomenclature Specification Manufacturer Work Package
Thread Lubricant GP460 Acheson Colloids Co. 1410 00
6315 Warren-Sharon Rd. 1411 00
P.O. Box 120 1412 00
Brookfield, OH 44403 1510 00
USA 1511 00
1512 00
1513 00
1514 00
1913 02
1913 03
1913 04
2411 00
2411 01
2412 00
2413 00
2510 00
2710 00
2711 00
4015 00
Wire Ties N/A Local Purchase 1112 01
Zinc Chromate Primer Fed Spec Local Purchase 1913 01
TT-P-1757 1916 00
2212 00
2213 00
2215 00
32 Change 6
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5. On-Site Expendables.
See table 4.
NOTE
Due to the variety of gaskets, packings, seals, etc., used during installa-
tion of external tubing, expendable materials are not listed. Refer to the
individual maintenance task (Reference SWP 1913 01, SWP 1913 02, SWP
1913 03, and SWP 1913 04.) and Illustrated Parts Breakdown
GEK 105060 for required parts.
Table 4. On-Site Expendables
Qty Per Work
Part No.* Nomenclature Engine Recommended Qty Package
102705 Element, Strainer Filter 1 – 4019 00
1375M50P03 Seal, O-ring (A/O seal) 1 – 2511 00
1375M50P04 Seal, O-ring (5R housing) 1 – 2511 00
140100-110 Packing, Preformed 3 – 1810 00
3011 00
1474M25P01 Seal Plug (Stage 5) 45 – 2413 00
1531M63P01 Seal Plug (Stage 3) 39 – 2413 00
1531M64P01 Seal Plug (Stage 4) 42 – 2413 00
1538M42P01 Gasket 1 – 1712 00
1538M42P02 Gasket 1 (ALT) – 1712 00
1754M91P01 Ring, Piston 6 – 2511 00
1754M91P02 Ring, Piston 6 (ALT) – 2511 00
2873-400 E-Seal 2 – 1713 00
78151-133 Packing, Preformed 1 – 4019 00
9009M32P01 Keywasher 9 – 2813 00
9009M74P03 Gasket, Round 1 – 1810 00
9011M60P01 Gasket, Seal 2 – 1810 00
1811 00
9013M28P01 Gasket, Seal 1 (ALT) – 1813 00
9013M28P02 Gasket, Seal 1 – 1813 00
9013M29P01 Gasket, Seal 1 (ALT) – 1813 00
9013M29P02 Gasket, Seal 1 – 1813 00
9013M30P02 Gasket, Seal 1 – 1813 00
9016M30P02 Seal Ring 90 – 1510 00
1511 00
1512 00
1513 00
1514 00
Change 6 33
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Table 4. On-Site Expendables (Continued)
Qty Per Work
Part No.* Nomenclature Engine Recommended Qty Package
9057M50P01 Seal 1 – 1810 00
9107M23P01 Gasket 2 – 1814 00
1815 00
9186M93G04 Screw, Machine 132 – 2511 00
9219M19P05 Shim 1 – 2610 00
9232M78P03 Nut, Plain Round 54 – 2511 00
9232M90P17 Nut Assembly, Self-locking 6 – 2511 00
(nozzle support)
9232M90P18 Nut Assembly, Self-locking 6 – 2511 00
(mini nozzle)
9234M17P05 Bolt, Slab-Head 54 – 2511 00
9283M41P04 Nut, Self-locking 24 – 2610 00
9365M41P117 Packing, Preformed 9 – 1112 00
1311 00
1410 00
2110 00
9365M41P122 Packing, Preformed 9 – 1112 00
1311 00
1410 00
2110 00
9365M41P229 Packing, Preformed 1 – 2813 00
9371M19P04 Seal 7 – 1511 00
1512 00
1513 00
1912 00
9371M19P06 Seal 6 – 1511 00
1512 00
1513 00
9371M19P08 Seal 4 – 1510 00
1511 00
1512 00
1514 00
9371M19P104 Seal 3 (ALT) – 1512 00
1912 00
9371M19P106 Seal 2 (ALT) – 1512 00
9371M19P10 Seal 10 – 1511 00
1512 00
1513 00
9371M19P110 Seal 4 (ALT) – 1512 00
9371M19P112 Seal 3 (ALT) – 1512 00
34 Change 6
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Table 4. On-Site Expendables (Continued)
Qty Per Work
Part No.* Nomenclature Engine Recommended Qty Package
9371M19P12 Seal 9 – 1511 00
1512 00
1513 00
9379M93P01 Gasket 1 – 1711 00
9382M94P02 Spring Retainer, Stages 6 and 8 127 – 2412 00
9382M95P05 Spring Retainer, Stages 9, 10, 12, 300 – 2412 00
and 13
9559M20G01/G02 Seal Ring 90 (ALT) – 1510 00
1512 00
1514 00
9607M05P21 Packing, Preformed 1 – 2210 00
9608M08G48 Gasket, Square Seal 2 – 1714 00
1916 00
9608M12P04 Gasket, Round 2 – 1813 00
2813 00
9693M18P06 Ring, Piston 6 (ALT) – 2511 00
AC-B244F-2440 Element, Filter 1 – 4021 00
AN123631 Rivet, Solid 18 – 2511 00
J1128P05 Ring, Seal - Metal 3 – 1518 00
J1128P12 Ring, Seal - Metal 2 – 1916 00
J219P02 Gasket, Seal 1 – 1813 00
J219P03 Gasket, Seal 4 – 1311 00
1312 00
1313 00
1811 00
J219P04 Gasket, Seal 7 – 1311 00
1312 00
1313 00
1811 00
1812 00
1813 00
1816 00
J219P05A Gasket, Seal 2 – 3011 00
J219P05 Gasket, Seal 4 – 1812 00
1813 00
J219P07 Gasket, Seal 2 – 1812 00
J221P010 Packing, Preformed (lube nozzle) 1 – 2511 00
J221P014 Packing, Preformed 1 – 3011 00
J221P113 Packing, Preformed 4 – 1710 00
J221P129 Packing, Preformed 2 – 2813 00
Change 6 35
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Table 4. On-Site Expendables (Continued)
Qty Per Work
Part No.* Nomenclature Engine Recommended Qty Package
J221P134 Packing, Preformed 2 – 3011 00
4015 00
J221P138 Packing, Preformed 1 – 2813 00
J221P140 Packing, Preformed 2 – 2813 00
J221P216 Packing, Preformed 1 – 1810 00
J221P219 Packing, Preformed 2 – 1815 00
J221P222 Packing, Preformed 2 – 1814 00
1815 00
J221P224 Packing, Preformed 2 – 1810 00
J221P260 Packing, Preformed 1 – 1812 00
J221P903 Packing, Preformed 2 – 1111 00
1310 00
J221P904 Packing, Preformed 14 – 1112 00
1311 00
1410 00
1810 00
1813 00
1814 00
1815 00
181700
3011 00
J221P905 Packing, Preformed 4 – 1910 00
4020 00
J221P906 Packing, Preformed 4 – 1810 00
1814 00
3011 00
J221P908 Packing, Preformed 7 – 1811 00
1814 00
3011 00
J221P910 Packing, Preformed 4 – 1811 00
1813 00
J221P912 Packing, Preformed 1 – 1815 00
J221P916 Packing, Preformed 1 – 1810 00
J626P04 Nut (After Shaft Cover) 7 – 2710 00
J626P09 Nut (Rear Drive Adapter Cover) 28 – 2710 00
J646P61B Bolt (5R A/O seal) 6 – 2511 00
J979P06 Nut (mini nozzle support) 54 – 2511 00
L22281P02 Gasket 1 – 1814 00
L28004P01 Gasket, Seal 1 – 1811 00
L28004P03 Gasket, Seal 1 (ALT) – 1811 00
36 Change 6
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WP 0001 00
Table 4. On-Site Expendables (Continued)
Qty Per Work
Part No.* Nomenclature Engine Recommended Qty Package
L43073P01 Gasket 2 – 1515 00
1515 01
L44818G01 Link, Fixed IGV Actuator Assembly AR _ 1112 01
(Zero Degree FIGV)
L44818G02 Link, Fixed IGV Actuator Assembly AR _ 1112 01
(Negative Five (-5) Degree
FIGV)
L45017G05 Nut, Adapter 1 – 2710 00
L45045P01 Bolt (Rear Drive Adapter Cover) 28 – 2710 00
L45066P01 Ring, Shaft 1 – 2710 00
L45921P01 Gasket, Seal 10 – 1510 00
1511 00
1512 00
1514 00
L47372P01 Packing, Preformed 58 – 2412 00
(Stage 5 Hi-Boss Case)
L47372P02 Packing, Preformed 96 – 2412 00
(Stages 3 and 4 Hi-Boss Case)
L47804P01 Nut, Coupling 1 – 2710 00
L47805P01 Ring, Retainer 1 – 2710 00
L47865P03 Spacer, Ring (Shim) 1 – 2710 00
L47865P04 Spacer, Ring (Shim) 1 – 2710 00
L47865P05 Spacer, Ring (Shim) 1 – 2710 00
L47865P06 Spacer, Ring (Shim) 1 – 2710 00
L47865P07 Spacer, Ring (Shim) 1 – 2710 00
L47865P08 Spacer, Ring (Shim) 1 – 2710 00
L47865P09 Spacer, Ring (Shim) 1 – 2710 00
L47865P10 Spacer, Ring (Shim) 1 – 2710 00
L47865P11 Spacer, Ring (Shim) 1 – 2710 00
L47865P12 Spacer, Ring (Shim) 1 – 2710 00
M83248/1-009 Packing, Preformed AR – 4017 00
M83248/1-110 Packing, Preformed 1 – 4021 00
M83248/1-243 Packing, Preformed 1 – 4021 00
M83248/1-905 Packing, Preformed 5 – 4020 00
M83248/1-910 Packing, Preformed 3 – 4020 00
M83248/1-912 Packing, Preformed 9 – 3011 00
4020 00
MS9202-042 Gasket 1 – 1517 00
NAS1593-121 Packing, Preformed 1 – 4020 00
Change 6 37
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WP 0001 00
Table 4. On-Site Expendables (Continued)
Qty Per Work
Part No.* Nomenclature Engine Recommended Qty Package
NAS1595-10 Packing, Preformed 2 – 4020 00
NAS1595-12 Packing, Preformed 3 – 4020 00
NAS1595-5 Packing, Preformed 7 – 4020 00
Packager-Supplied Gasket 3 – 1813 00
Packager-Supplied Seal, Inlet Flange 4 – 1510 00
1511 00
1512 00
1514 00
* Latest active part number shown. Check interchangeability issues in Illustrated Parts
Breakdown for alternate parts that may be applicable to specific engine configura-
tions.
Change 6 38
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WP 1110 00
0WP 1110 00
WORK PACKAGE
TECHNICAL PROCEDURES
AXIAL INLET CENTERBODY ASSEMBLY
REPLACEMENT - HOT END DRIVEN
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-4 ...... 1
Alphabetical Index
Subject Page
Axial Inlet Centerbody Assembly Installation............................................................................ 3
Axial Inlet Centerbody Assembly Removal ............................................................................... 3
Change 1 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1110 00
1. Introduction.
This work package contains instructions for removal and installation of the axial inlet centerbody
assembly. (Reference kit, P/N 682L204, Fig 74 IPB).
2. Reference Material.
None required.
3. Support Equipment.
Nomenclature Part No.
Driver, No. 10 Torq-Set Local Purchase
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
5. Expendable Material.
None required.
2 Change 1
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WP 1110 00
6. Axial Inlet Centerbody Assembly Removal.
See figure 1.
NOTE
Forward and aft centerbody are matched parts and are kept
together as an assembly.
A. Using marking pen, matchmark aft centerbody to forward centerbody.
B. Using No. 10 Torq-Set driver, remove 13 screws that secure forward centerbody
(Detail A). Remove forward centerbody.
C. Remove 46 nuts, 92 washers, and 46 bolts that secure aft centerbody to inlet frame or
variable inlet guide vane (VIGV) forward inner casing (Detail B). Remove aft
centerbody.
1
7. Axial Inlet Centerbody Assembly Installation.
See figure 1.
NOTE
Forward and aft centerbody are matched parts and are kept
together as an assembly.
A. Using 46 bolts, 92 washers, and 46 nuts (Detail B) install aft centerbody onto inlet
frame or VIGV forward inner casing. Boltheads face forward. Position one washer
under bolthead, and one washer under nut. Tighten bolts to 55-70 lb in. (6.3-7.9 N·m)
of torque.
B. Align matchmarks and install forward centerbody onto aft centerbody. Secure with
13 screws (Detail A). Using No. 10 Torq-Set driver, tighten screws to 33-37 lb in.
(3.8-4.1 N·m) of torque.
C. Inspect centerbody for proper seating.
Change 1 3
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WP 1110 00
Figure1. Axial Inlet Centerbody Assembly
4 Change 1
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WP 1111 00
WP 1111 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR INLET
TEMPERATURE/PRESSURE (T2/P2) SENSOR
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 0
6 Blank ...... 0
Alphabetical Index
Subject Page
Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor Installation .................. 3
Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor Removal...................... 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1111 00
1. Introduction.
This work package contains instructions for removing and installing the low pressure compressor
inlet temperature/pressure (T2/P2) sensor.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon - Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Petrolatum Fed Spec VV-P-236
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P903 1
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WP 1111 00
6. Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor Removal.
See figure 1.
A. If installed, disconnected pressure sensing tube from T2/P2 sensor pressure port per
packager's manual.
NOTE
If same T2/P2 sensor will be reinstalled, proceed to step C.
B. Remove plug or fitting from T2/P2 sensor pressure port. Discard preformed
packing.
1
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
C. Tag and disconnect electrical connector from T2/P2 sensor integral lead.
D. Remove jamnut that secures T2/P2 sensor integral lead to electrical interface panel.
E. Remove integral lead from spring clips.
F. Remove bolts that secure T2/P2 sensor to variable inlet guide vane (VIGV) assembly
case. Remove T2/P2 sensor.
7. Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor Installation.
See figure 1.
A. Install T2/P2 sensor onto inlet frame or VIGV assembly case. Using two bolts, secure
T2/P2 sensor to inlet frame or VIGV assembly case. Tighten bolts to 33-37 lb in.
(3.7-4.1 N·m) of torque. Safety-wire bolts.
B. Using jamnut, secure T2/P2 sensor integral lead to electrical interface panel. Tighten
jamnut to 25-35 lb in. (2.8-3.9 N·m) of torque. Safety-wire jamnut.
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WP 1111 00
Figure 1. Low Pressure Compressor Inlet Temperature/Pressure (T2/P2) Sensor
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WP 1111 00
C. Connect electrical connector to T2/P2 sensor integral lead as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
D. Install integral lead into spring clips.
NOTE
If plug or fitting is already installed, proceed to step G.
E. Lubricate preformed packing, P/N J221P903, with petrolatum, and install onto plug or
fitting.
F. Install plug or fitting into T2/P2 sensor pressure port. Tighten plug or fitting to
90-100 lb in. (10.2-11.3 N·m) of torque. Safety-wire plug.
G. If present, connect pressure sensing tube to fitting in T2/P2 sensor pressure port per
packager's manual.
5/(6 Blank)
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WP 1112 00
WP 1112 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE INLET GUIDE VANE (VIGV) ACTUATOR
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 10 ...... 0
Alphabetical Index
Subject Page
Variable Inlet Guide Vane Actuator Installation ......................................................................... 7
Variable Inlet Guide Vane Actuator Length Preset Adjustment Using Check Fixture, 1C9403 6
Variable Inlet Guide Vane Actuator Removal............................................................................. 3
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1112 00
1. Introduction.
This work package contains instructions for removing and installing the variable inlet guide vane
(VIGV) actuators.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Inlet Guide Vane (VIGV) System Check WP 1113 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Hydraulic Actuator Unit 1C3569G3
Adapter Set, Pressure Test/Rig - VIGV, 1C9393G01
VBV, VSV System
Fixture, Check VSV/VIGV Actuator 1C9403G01
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Soap Solution Local Purchase
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P904 2
Packing, Preformed 9365M41P117 2
Packing, Preformed 9365M41P122 2
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WP 1112 00
6. Variable Inlet Guide Vane Actuator Removal.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure that location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
A. Tag and disconnect electrical connector from VIGV actuator.
NOTE
Ensure that lube oil supply is shut off before disconnecting tubing.
B. Disconnect tubing as follows (figure 1):
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do
not inhale, ingest, or let this material touch you. Irritant.
Personal protective equipment required. Use mechanical
exhaust ventilation - if not available, use an approved respi-
rator.
(1) Position a waste fluid container beneath VIGV actuator. Disconnect drain line
from drain adapter.
(2) Disconnect drain adapter from VIGV actuator. Slide drain adapter away from
VIGV actuator port to expose coupling nut.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
(3) Disconnect coupling nut from VIGV actuator fitting.
(4) Remove and discard preformed packing from drain adapter.
1
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WP 1112 00
Figure 1. Variable Inlet Guide Vane (VIGV) Tubing
CAUTION
Do not change adjustment of actuator rod end. Any movement or
adjustment requires that paragraph 7 of this work package be
performed and VIGV actuation system rigging be checked per
WP 1113 00.
C. If actuator-to-ring bracket must be removed, reference WP 1113 00. Remove
actuator-to-ring brackets.
D. Remove nut, bolt, and bushings that secure VIGV actuator rod end (figure 2).
E. Remove nut and bolt that secure VIGV actuator to bearing block. Remove VIGV
actuator.
F. Remove fittings from VIGV actuator. Remove and discard preformed packings.
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WP 1112 00
2
Figure 2. Variable Inlet Guide Vane (VIGV) Actuator
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WP 1112 00
7. Variable Inlet Guide Vane Actuator Length Preset Adjustment Using Check Fixture,
1C9403.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
CAUTION
• Maintain 250.0 psi (1,724 kPa) on actuator, at the fully
extended position, when adjusting rod end, or preset
adjustment will be incorrect.
• Use hydraulic actuator unit, 1C3569G3, with engines that use
lubricating oil, MIL-L-23699. Do not intermix lubricating oils,
MIL-L-7808 and MIL-L-23699, or damage will occur.
NOTE
This procedure is to be performed before installing a new actuator
or in the event actuator rod-end adjustment is disturbed during
removal/installation.
A. Connect hydraulic actuator unit, 1C3569, to actuator. Supply 250.0 psi (1,724 kPa) to
extend actuator to fully extended position. Maintain pressure throughout adjustment
procedure.
B. Loosen jamnut that secures actuator rod end.
C. Adjust rod end so that actuator slides freely onto fixture, 1C9403. See figure 3.
D. Tighten jamnut to secure rod end. Safety-wire jamnut.
E. Release pressure and remove hydraulic actuator unit, 1C3569.
3
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WP 1112 00
Figure 3. Actuator Length Preset Using Check Fixture, 1C9403
8. Variable Inlet Guide Vane Actuator Installation.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not inhale,
ingest, or let this material touch you. Irritant. Personal protective
equipment required. Use mechanical exhaust ventilation - if not avail-
able, use an approved respirator.
NOTE
If installing a new actuator, or in the event actuator rod-end
adjustment is disturbed during removal/installation, perform
paragraph 7 of this work package.
A. Lubricate preformed packings, P/N J221P904 and P/N 9365M41P122 (figure 1), with
lubricating oil and install into groove of fitting.
B. Install fitting into VIGV actuator. Tighten fitting to 135-150 lb in. (15.3-16.9 N·m) of
torque.
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WP 1112 00
C. Apply thread lubricant to threads of bearing actuator block bolt and secure VIGV
actuator onto actuator bearing block with nut and bolt. See figure 2, view B. Bolthead
faces aft. Tighten nut to 360-400 lb in. (40.7-45.2 N·m) of torque.
D. Install actuator-to-ring brackets per WP 1113 00.
E. Apply thread lubricant to threads of VIGV actuator rod-end bolt, detail A. Using bolt
(bolthead outboard) and nut, secure actuator-to-ring brackets onto VIGV actuator rod
end. Tighten nut to 360-400 lb in. (40.7-45.2 N·m) of torque.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do
not inhale, ingest, or let this material touch you. Irritant.
Personal protective equipment required. Use mechanical
exhaust ventilation - if not available, use an approved respi-
rator.
F. Lubricate preformed packing, P/N 9365M41P117 (figure 1), with lubricating oil and
install into drain adapter.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
G. Connect tubing coupling nut onto VIGV actuator fitting. Tighten coupling nut to
270-300 lb in. (30.6-33.9 N·m) of torque.
H. Leak-check head- and rod-end fittings as follows:
CAUTION
Use hydraulic actuator unit, 1C3569G3, with engines that use
lubricating oil, MIL-L-23699. Do not intermix lubricating oil,
MIL-L-7808 and MIL-L-23699, or damage will occur.
(1) Install reducers from pressure test adapter set, 1C9393, onto hydraulic actuator
unit, 1C3569. Tighten reducers to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Position waste fluid container under hydraulic control unit (HCU).
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WP 1112 00
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not inhale,
ingest, or let this material touch you. Irritant. Personal protective
equipment required. Use mechanical exhaust ventilation - if not
available, use an approved respirator.
CAUTION
Ensure connecting fitting is restrained when loosening or tightening
coupling nut. Failure to comply may result in part damage.
(3) Disconnect head tube from HCU. Install head tube on -4 to -10 reducer. Tighten
coupling nut to 650-770 lb in. (73.5-87.0 N·m) of torque.
(4) Disconnect rod tube from HCU. Install rod tube on -4 to -8 reducer. Tighten
coupling nut to 450-550 lb in. (50.9-62.1 N·m) of torque.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
(5) Apply 200-250 psi (1,379-1,724 kPa) to head tube and hold for a minimum of 2
minutes. Check head tube/actuator connection for leakage.
(6) Apply 200-250 psi (1,379-1,724 kPa) to rod tube and hold for a minimum of 2
minutes. Check rod tube/actuator connection for leakage.
(7) If required, check VIGV actuation system per WP 1113 00.
(8) Disconnect hydraulic actuator unit, 1C3569. Remove reducers.
(9) Connect head tube onto HCU. Tighten coupling nut to 650-770 lb in.
(73.5-87.0 N·m) of torque.
(10) Connect rod tube onto HCU. Tighten coupling nut to 450-550 lb in.
(50.9-62.1 N·m) of torque.
I. Slide drain adapter over coupling nut and connect onto VIGV actuator port.
Hand-tighten drain adapter.
J. Leak-check drain adapters as follows:
(1) Connect source of clean, dry, regulated shop air or nitrogen onto drain line fitting
on drain adapter.
9
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1112 00
WARNING
• Serious injury can occur when applying pneumatic pres-
sure. Eye protection is required. Relieve pressure before
disconnecting lines and fittings.
• Nitrogen, BB-N-411, can displace oxygen in enclosed
areas. Use in a well-ventilated area.
(2) Apply 50-55 psi (345-379 kPa) to drain adapter. Shut off pressure and monitor.
Pressure shall not drop off more than 10 psi (69 kPa) in 2 minutes.
(3) If pressure drop limit is exceeded, use soap solution to detect leak. Repair, as
required, and repeat leak check.
(4) Disconnect test equipment from drain adapter.
(5) Connect drain line to drain adapter. Tighten coupling nut to 270-300 lb in.
(30.6-33.9 N·m) of torque.
K. Connect electrical connector to VIGV actuator as follows:
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling back shell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
10
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GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1112 01
SUBORDINATE WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE INLET GUIDE VANE (VIGV) ACTUATOR
REPLACEMENT WITH FIXED LINK
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-7 ...... 0
8 Blank ...... 0
Alphabetical Index
Subject Page
Fixed Link Replacement with Variable Inlet Guide Vane Actuator............................................ 5
Variable Inlet Guide Vane Actuator Replacement with Fixed Link............................................ 3
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Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1112 01
1. Introduction.
This subordinate work package contains instructions for replacing the VIGV actuators with fixed
links.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Inlet Guide Vane (VIGV) Actuator Replacement WP 1112 00
Variable Inlet Guide Vane (VIGV) System Check WP 1113 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-PRF-23699F (C/I)
Safety Wire (0.032 inch) R297P04
Thread Lubricant GP460
Wire Ties -
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Link, Fixed IGV Actuator Assembly L44818G01 AR
(Zero Degree FIGV)
Link, Fixed IGV Actuator Assembly L44818G02 AR
(Negative Five (-5) Degree FIGV)
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GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1112 01
6. Variable Inlet Guide Vane Actuator Replacement with Fixed Link.
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
A. Tag and disconnect electrical connector from VIGV actuator. Wire tie electrical cable,
figure 1, to adjacent tube.
NOTE
Ensure lube oil supply is shut off before disconnecting tubing.
B. Disconnect rod-end, head-end, and drain tubing as follows (figure 1):
NOTE
Clamp removal only applies to the left-side actuator.
(1) Remove two bolts and flat washers that secure clamp to tubes and bracket.
Remove clamp.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do
not inhale, ingest, or let this material touch you. Irritant.
Personal protective equipment required. Use mechanical
exhaust ventilation - if not available, use an approved respi-
rator.
(2) Position waste fluid container beneath VIGV actuator.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
(3) Tag and disconnect drain tube, and rod- and head-end tubes from tubes and
manifolds near bracket.
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SWP 1112 01
Figure1. Variable Inlet Guide Vane Tubing
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C. Remove nut, bolt, and bushings that secure VIGV actuator rod-end.
D. Remove nut and bolt that secure VIGV actuator to bearing block. Remove VIGV actuator
and tubing as an assembly.
E. Install caps or plugs onto ends of rod-end, head-end, and drain tubes. Tighten caps and
plugs to 270-300 lb in. (30.5-33.8 N·m) of torque. Safety-wire plugs and caps.
F. Reinstall clamp to remaining tube and secure bracket with two bolts and washers.
Tighten bolts to 33-37 lb in. (3.7-4.1 N·m) of torque.
NOTE
• Install the correct fixed link for the desired IGV configuration. Use
the L44818G01 for a Zero Degree Fixed IGV configuration or
L44818G02 for a Negative Five Degree Fixed IGV configuration.
• Clevis end of fixed link has two different size holes. Flanged
bushing is installed in largest hole.
G. Ensure bushings are installed in holes in clevis end of fixed link.
H. Apply thread lubricant onto threads of bearing actuator block bolt and secure fixed link
onto actuator bearing block with nut and bolt. See figure 2. Bolthead faces aft. Tighten
nut to360-400 lb in. (40.6-45.1 N·m) of torque.
I. Apply thread lubricant onto threads of fixed link rod-end bolt. Using bolt (bolthead
outboard) and nut, secure actuator-to-ring brackets onto fixed link rod-end. Tighten nut
to 360-400 lb in. (40.6-45.1 N·m) of torque.
J. Install protective caps or plugs onto tubes or hoses still attached to actuator.
K. Repeat step A. through step J. for remaining actuator.
L. Store actuator, with tubes/hoses installed, for reuse.
7. Fixed Link Replacement with Variable Inlet Guide Vane Actuator.
A. Remove nut and bolt that secure fixed link onto actuator bearing block (figure 2).
B. Remove nut and bolt that secures fixed link rod-end to actuator-to-ring brackets and
remove fixed link.
C. Remove two bolts and flat washers that secure clamp to bracket.
D. Check and adjust actuator rod length per WP 1112 00.
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SWP 1112 01
Figure2. Fixed Link Installation
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E. Remove caps and plugs from tubes or hoses.
F. Apply thread lubricant onto threads of VIGV actuator rod-end bolt, figure 1, using
bolt (bolthead outboard) and nut. Secure VIGV actuator rod-end onto actuator-to-ring
brackets. Tighten nut to 360-400 lb in. (40.6-45.1 N·m) of torque.
G. Apply thread lubricant onto threads of actuator bearing block bolt and secure VIGV
actuator onto bearing block with bolt and nut. Bolthead faces aft. Tighten nut to
360-400 lb in.(40.6-45.1 N·m) of torque.
H. Connect drain and rod- and head-end tubes to tubes at clamp.
I. Tighten drain tube and rod- and head-end tubes to 270-300 lb in. (30.5-33.8 N·m) of
torque.
J. Using two bolts and flat washers, reinstall clamp onto bracket, holding drain, rod-,
and head-end tubes.
K. Connect electrical connector VIGV actuator as follows:
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
L. If needed, rig VIGV per WP 1113 00.
7/(8 Blank)
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WP 1113 00
WP 1113 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE INLET GUIDE VANE (VIGV) SYSTEM
CHECK
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1-9 ...... 0
10 Blank . . . . . . 0
Alphabetical Index
Subject Page
Variable Inlet Guide Vane System Check ................................................................................... 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1113 00
1. Introduction.
This work package contains instructions for checking the variable inlet guide vane (VIGV)
system. Before performing this work package, ensure the following conditions exist:
• VIGV flaps are installed.
• Lever arms are installed in actuating rings.
• VIGV actuating ring is installed.
• VIGV actuators are installed and connected.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Inlet Guide Vane (VIGV) Actuator Replacement WP 1112 00
3. Support Equipment.
Nomenclature Part No.
Hydraulic Actuator Unit 1C3569G3
Rigging Set, VIGV 1C9359G02
Adapter Set, Pressure Test/Rig - VIGV, 1C9393G01
VBV, VSV
4. Consumable Material.
Nomenclature Specification
Thread Lubricant GP460
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Shim, Actuator Ring L45101P01-P08 AR
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WP 1113 00
6. Variable Inlet Guide Vane System Check.
CAUTION
Use hydraulic actuator unit, 1C3569G3, with engines that use
lubricating oil, MIL-L-23699. Do not intermix lubricating oil,
MIL-L-7808 and MIL-L-23699, or damage will occur.
A. Connect hydraulic actuator unit, 1C3569, as follows (figures 1 and 2):
(1) Install reducers from adapter set, 1C9393, onto hydraulic actuator unit, 1C3569
(figure 1). Tighten to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Position waste fluid container under hydraulic control unit (HCU) (figure 2).
1
Figure1. Hydraulic Actuator Unit, 1C3569
2
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WP 1113 00
Figure2. HCU Tube Locations
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WP 1113 00
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
CAUTION
Ensure connecting fitting is restrained when loosening or tightening
coupling nut. Failure to comply may result in part damage.
(3) Disconnect head tube from HCU. Install head tube onto -4 to -10 reducer. Tighten
coupling nut to 650-770 lb in. (73.5-87.0 N·m) of torque.
(4) Disconnect rod tube from HCU. Install rod tube onto -4 to -8 reducer. Tighten
coupling nut to 450-550 lb in. (50.9-62.1 N·m) of torque.
B. Check VIGV system as follows:
WARNING
• When actuating VIGV system, keep hands clear of mov-
ing parts, or serious injury may result.
• Serious injury can occur when applying hydraulic pres-
sure. Eye protection is required. Relieve pressure before
disconnecting lines and fittings.
(1) Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VIGV system to
full open and full closed positions several times. System shall operate smoothly
throughout entire range of travel in both directions.
(2) Check all fittings for leaks through VIGV system to full travel. Correct, as
required.
NOTE
VIGV position indication is read at indicator on control panel.
Control panel shall be powered up to read VIGV position indication.
(3) Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VIGV system to
full open position. VIGV position indicator shall read 100 ± 1 percent (full open).
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WP 1113 00
CAUTION
VIGV actuating ring mount bolts are anodized. Do not disturb
mount bolts, or coating damage may occur.
(4) Insert actuator locating pin, 1C9359P03, through rig fixture -10 degree hole.
Actuator locating pin, P03, shall slide freely. See figure 3. If difficulty is
encountered, loosen both actuator-to-ring brackets at actuator rod ends as follows:
(a) Release hydraulic pressure from system.
(b) Loosen nuts that secure both VIGV actuator rod ends to actuation-to-ring
brackets. See figure 4.
(c) Insert pin so that actuator locating pin, figure 3, slides freely into rig
fixture -10 degree hole.
4
3
(5) Remove bolts and nuts that secure actuator rod ends to actuator-to-ring brackets.
See figure 4, detail A.
(6) Apply hydraulic pressure so both actuator rod ends are fully extended.
(7) Position actuator-to-ring brackets onto actuation ring so holes align with actuator
rod ends. If required, loosen nuts that secure actuator-to-ring brackets to actuation
ring.
(8) Apply thread lubricant to threads of actuator rod-end bolts, detail A. Using bolts
and nuts, secure actuator rod-ends onto actuator-to-ring brackets. Boltheads are
outboard. Tighten nuts to 360-400 lb in. (40.7-45.2 N·m) of torque.
(9) Tighten nuts that attach actuator-to-ring brackets onto actuation ring to
380-420 lb in. (43.0-47.4 N·m) of torque.
(10) Remove actuator locating pin, 1C9359P03. See figure 3.
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WP 1113 00
Figure3. VIGV Rig Pin Installation
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WP 1113 00
Figure 4. VIGV Actuators and Mount Brackets Removal/Installation
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WP 1113 00
CAUTION
Ensure connecting fitting is restrained when loosening or
tightening coupling nut. Failure to comply may result in part
damage.
C. Disconnect hydraulic actuator unit, 1C3569. Remove reducers. See figure 1.
D. Connect head tube onto HCU. Tighten coupling nut to 650-770 lb in. (73.5-87.0 N·m)
of torque. See figure 2.
E. Connect rod tube onto HCU. Tighten coupling nut to 450-550 lb in. (50.9-62.1 N·m)
of torque.
F. If gas turbine still has VIGV difference alarm, perform shim adjustments as follows:
(1) Remove VIGV actuators per WP 1112 00. Check and reset rod-end per
WP 1112 00. Reinstall actuators.
(2) Locate actuation ring support blocks bolted to outer VIGV case. Measure
clearance between blocks and actuation ring inside diameter, 14 places on
L45027G03, and 8 places on L45027G04 and later configurations.
(3) Plot and review clearances at support blocks 180 degrees opposite each other.
Example: 12:00 o'clock position equals 0.000 inch (0.00 mm) clearance, 6:00
o'clock position equals 0.040 inch (1.02 mm) clearance. Obtain shims L45101P01
through P08. Remove two bolts attaching support block to VIGV case at 12:00
o'clock position. Install shim to correct clearance at 6:00 o'clock position to 0.020
inch (0.51 mm). Install bolts and tighten to 33-37 lb in. (3.7-4.2 N·m) of torque.
NOTE
Not all support block locations will have a corresponding block
at 180 degrees opposite. If no block is 180 degrees opposite and
clearance is greater than 0.020 inch (0.51 mm), add shims to
reduce clearance to 0.020 inch (0.51 mm).
(4) Proceed in clockwise direction to next support block and repeat step (3) to adjust
clearances opposite locations to be as equal as shim thicknesses will allow.
(5) After shim corrections are complete, perform rig check per this WP.
9/(10 Blank)
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WP 1114 00
WP 1114 00
WORK PACKAGE
TECHNICAL PROCEDURES
FORWARD SEAL COVER PLATE REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-3 ...... 0
4 Blank ...... 0
Alphabetical Index
Subject Page
Forward Seal Cover Plate Installation ........................................................................................ 3
Forward Seal Cover Plate Removal ............................................................................................ 3
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WP 1114 00
1. Introduction.
This work package contains instructions for removing and installing the forward seal cover plate.
2. Reference Material.
None required.
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Thread Lubricant GP460
5. Expendable Material.
None required.
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WP 1114 00
6. Forward Seal Cover Plate Removal.
Remove two bolts (figure 1) and forward seal cover plate from inlet frame at 6:00 o'clock
position.
7. Forward Seal Cover Plate Installation.
A. Position variable inlet guide vane (VIGV) or inlet frame inner case so that forward
seal opening is at 6:00 o'clock position. See figure 1.
B. Using thread lubricant, coat washer faces and threads of two bolts.
C. Position cover plate over opening in VIGV or inlet frame inner case at 6:00 o'clock
position (figure 1).
D. Install two bolts. Tighten bolts to 105-115 lb in. (11.9-12.9 N·m) of torque.
1
Figure1. Forward Seal Cover Plate Replacement
3/(4 Blank)
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WP 1210 00
2WP 1210 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR SPEED (XN2)
SENSOR REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-7 ...... 0
8 Blank ...... 0
Alphabetical Index
Subject Page
LPC Rotor Speed Sensor Plug Installation (Interim Configuration) .......................................... 5
LPC Rotor Speed Sensor Plug Removal (Interim Configuration).............................................. 5
LPC Rotor Speed Sensor Plug Installation (Interim Configuration) .......................................... 5
LPC Rotor Speed (XN2) Sensor Removal (Initial Configuration) ............................................. 3
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WP 1210 00
1. Introduction.
NOTE
There are three possible speed (XN2) sensor configurations. The first is
the LPC module with the speed (XN2) sensor installed. The second is with
a speed sensor plug installed. The third is with neither the sensor or plug
installed.
This work package contains instructions for removing and installing the low pressure compressor
(LPC) (XN2) speed sensors.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Molybdenum Disulfide Lubricant MIL-L-25681
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Shim, Laminated 9107M55P01 3
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6. LPC Rotor Speed (XN2) Sensor Removal (Initial Configuration).
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
A. Tag and disconnect electrical connector from speed (XN2) sensor. See figure 1.
B. Remove bolts and washers that secure speed (XN2) sensor to LPC stator case.
C. Remove speed (XN2) sensor and laminated shim. Discard laminated shim.
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WP 1210 00
1 Figure 1. Low Pressure Compressor Rotor (XN2) Speed Sensor
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7. LPC Rotor Speed Sensor Plug Removal (Interim Configuration).
A. Remove bolts and washes that secure speed sensor plug to LPC stator case. See
figure 1.
B. Remove speed sensor plug and laminated shim.
8. LPC Rotor Speed Sensor Plug Installation (Interim Configuration).
A. If shim is not reused or new speed sensor is installed, calculate required shim
thickness as follows. Otherwise, proceed to step C.
(1) Measure dimension A on speed sensor. See figure 2.
(2) Measure dimension B on LPC stator case. See figure 3.
(3) Calculate shim thickness as follows:
Calculated Shim Thickness (inches) = 0.182 inch + A - B
Calculated Shim Thickness (metric) = 4.623 mm + A - B
(4) Stack shims, as required, to exceed calculated shim thickness. Peel away
laminated shim until measured shim is within +/- 0.004 inch (0.101 mm) of
calculated shim thickness. Use new laminated shim, P/N 9107M55P01, if
required.
Figure 2. Low Pressure Compressor Rotor Speed Sensor - Dim A
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Figure 3. Compressor Stator Case - Dim B
B. Apply molybdenum disulfide lubricant onto threads of bolts.
C. Install laminated shim and speed (XN2) sensor onto LPC stator case.
D. Using four washers and bolts, secure (XN2) speed sensor onto LPC stator case.
Tighten bolts to 33-37 lb in. (3.7-4.2 N·m) of torque.
E. Connect electrical connector to speed (XN2) sensor as follows:
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
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WP 1210 00
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps 2 and (3), as required. It may be necessary to loosen lead clamps
that restrict mating.
9. LPC Rotor Speed Sensor Plug Installation (Interim Configuration).
A. Apply molybdenum disulfide lubricant to threads of bolts.
B. Install laminated shim and speed sensor plug onto LPC stator case.
C. Using four washers and bolts, secure speed sensor plug to case. Tighten bolts to
33-37 lb in. (3.8-4.1 N·m) of torque.
7/(8 Blank)
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WP 1310 00
0WP 1310 00
WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR INLET
TEMPERATURE/PRESSURE (T25/P25) SENSOR
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 0
6 Blank ...... 0
Alphabetical Index
Subject Page
High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor Installation ............. 3
High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor Removal................. 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1310 00
1. Introduction.
This work package contains instructions for removing and installing the high pressure compressor
inlet temperature/pressure (T25/P25) sensor.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Petrolatum Fed Spec VV-P-236
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P903 1
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WP 1310 00
6. High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor Removal.
See figure 1.
A. If installed, disconnect pressure sensing tube from T25/P25 sensor pressure port per
packager's manual.
NOTE
If same T25/P25 sensor will be reinstalled, proceed to step C
B. Remove plug or fitting and preformed packing from T25/P25 sensor pressure port.
Discard preformed packing.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
C. Tag and disconnect off engine cable from integral lead.
D. Remove jamnut that secures integral lead to electrical interface panel.
E. Remove integral lead from spring clips.
F. Remove two bolts that secure T25/P25 sensor to compressor front frame. Remove
T25/P25 sensor.
7. High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor Installa-
tion.
See figure 1.
A. Install T25/P25 sensor onto compressor front frame. Using two bolts, secure T25/P25
sensor to compressor front frame. Tighten bolts to 33-37 lb in. (3.8-4.1 N·m) of
torque. Safety-wire bolts.
B. Using jamnut, secure integral lead to electrical interface panel. Tighten jamnut to
25-35 lb in. (2.9-3.9 N·m) of torque. Safety-wire jamnut.
1
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Figure 1. High Pressure Compressor Inlet Temperature/Pressure (T25/P25) Sensor
C. Connect off engine cable to integral lead as follows:
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while wig-
gling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
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NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
D. Install integral lead in spring clips.
NOTE
If plug or fitting is already installed, proceed to step G.
E. Lubricate preformed packing, P/N J221P903, with petrolatum, and install onto plug or
fitting.
F. Install plug or fitting into T25/P25 sensor pressure port. Tighten plug or fitting to
90-100 lb in. (10.2-11.3 N·m) of torque. Safety-wire plug.
G. If present, connect pressure sensing tube to fitting in T25/P25 sensor pressure port per
packager's manual.
5/(6 Blank)
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WP 1311 00
0WP 1311 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE BYPASS VALVE (VBV) ACTUATOR
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 12
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 11 ...... 0
12 Blank . . . . . . 0
Alphabetical Index
Subject Page
Variable Bypass Valve Actuator Installation............................................................................... 5
Variable Bypass Valve Actuator Removal .................................................................................. 3
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WP 1311 00
1. Introduction.
This work package contains instructions for removing and installing the six variable bypass valve
(VBV) actuators.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Bypass Valve (VBV) System Check WP 1312 00
Front Frame Air Collector Replacement WP 2310 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Hydraulic Actuator Unit 1C3569G3
Adapter Set, Pressure Test/Rig - VIGV, 1C9393G01
VBV, VSV
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Molybdenum Disulfide Lubricant MIL-L-25681
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Soap Solution Local Purchase
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal (Rod-End) J219P03 1
Gasket, Seal (Head-End) J219P04 1
Packing, Preformed J221P904 1
Packing, Preformed 9365M41P117 1
Packing, Preformed 9365M41P122 1
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WP 1311 00
6. Variable Bypass Valve Actuator Removal.
A. Remove access panels from air collector, as required, to gain access per WP 2310 00.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure that location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
B. Tag and disconnect electrical connector from VBV actuator.
C Disconnect tubing from VBV actuator as follows (figure 1):
1
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not inhale,
ingest, or let this material touch you. Irritant. Personal protective
equipment required. Use mechanical exhaust ventilation - if not avail-
able, use an approved respirator.
(1) Position a waste fluid container beneath VBV actuator. Disconnect drain line
from drain adapter.
(2) Disconnect drain adapter from VBV actuator. Slide drain adapter away from
VBV actuator port to expose coupling nut.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
(3) Disconnect coupling nut from VBV actuator fitting.
(4) Remove and discard preformed packings.
D. If required, remove air collector seal from VBV actuator per WP 2310 00.
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Figure 1. VBV Actuator Tubing
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WP 1311 00
CAUTION
Do not change adjustment of clevis or actuator rod end. Any
movement or adjustment of clevis or actuator rod end length
requires that VBV actuation system rigging be checked.
E. Remove nut, washer, and bolt that secure clevis to bellcrank (figure 2).
2
F. Remove bolt and washer that secure VBV actuator mount leg to front frame.
G. Remove nuts and washers that secure VBV actuator mount studs to front frame.
Remove VBV actuator.
H. Remove nut and bolt that secure clevis to VBV actuator rod end. Remove clevis.
I. Remove fitting from VBV actuator (figure 1). Remove and discard preformed
packing.
7. Variable Bypass Valve Actuator Installation.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal pro-
tective equipment required. Use mechanical exhaust ventilation - if
not available, use an approved respirator.
A. Lubricate preformed packings, P/N J221P904 and P/N 9365M41P122, with l
ubricating oil and install into packing groove of fitting (figure 1).
B. Install fitting into VBV actuator. Tighten fitting to 135-150 lb in. (15.3-16.9 N·m) of
torque.
C. Apply molybdenum disulfide lubricant onto threads of all bolts and mount studs
figure 2.
D. Using bolt and nut, install clevis onto VBV actuator rod end. Tighten nut to
100-130 lb in. (11.3-14.6 N·m) of torque.
E. Install VBV actuator onto front frame. Position VBV actuator so that clevis retaining
bolt bolthead faces inboard.
F. Using washers and nuts, secure VBV actuator onto front frame. Tighten nuts to
55-70 lb in. (6.3-7.9 N·m) of torque.
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Figure 2. VBV Actuator
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G. Using bolt and washer, secure VBV actuator mount leg onto front frame. Tighten bolt
to 55-70 lb in. (6.3-7.9 N·m) of torque.
H. Using bolt, washer, and nut, secure clevis onto bellcrank. Bolthead faces inboard,
washer under nut. Tighten nut to 100-130 lb in. (11.3-14.6 N·m) of torque. Restrain
bolt during tightening procedure using 0.125-inch (3.175 mm) Allen wrench.
I. If required, install air collector seal as follows:
(1) Apply molybdenum disulfide lubricant onto threads of air collector seal retaining
screws.
(2) Install air collector seal and secure with screws.
(3) Tighten screws to 55-70 lb in. (6.3-7.9 N·m) of torque.
J. Lubricate preformed packing, P/N 9365M41P117, with lubricating oil and install into
drain adapter (figure 1).
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
K. Connect tubing coupling nut onto VBV actuator fittings. Tighten coupling nut to
270-300 lb in. (30.5-33.9 N·m) of torque.
L. Leak-check head- and rod-end fittings as follows (figure 3):
(1) Remove bolts and washers that secure VBV head hose (head-end) to hydraulic
control unit (HCU). Remove seal gasket.
(2) Install seal gasket, P/N J219P04, onto VBV head hose adapter from adapter set,
1C9393. Using washers and bolts, secure adapter onto head hose. Tighten bolts
to 33-37 lb in. (3.8-4.1 N·m) of torque.
(3) Remove bolts and washers that secure VBV rod hose (rod-end) to HCU. Remove
seal gasket.
(4) Install seal gasket, P/N J219P03, onto VBV rod hose adapter from adapter set,
1C9393. Using washers and bolts, secure adapter to rod hose. Tighten bolts
to 33-37 lb in. (3.8-4.1 N·m) of torque.
3
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WP 1311 00
Figure 3. Leak Check
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CAUTION
Use hydraulic actuator unit, 1C3569G3, with engines that use
lubricating oil, MIL-L-23699. Do not intermix lubricating oil,
MIL-L-7808 and MIL-L-23699, or damage will occur.
(5) Connect hydraulic actuator unit, 1C3569, to hose adapters. Tighten fittings
to 135-150 lb in. (15.3-16.9 N·m) of torque.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
(6) Apply 200-250 psi (1,379-1,724 kPa) to head tube and hold for a minimum of
2 minutes. Check head hose/actuator connection for leakage.
(7) Apply 200-250 psi (1,379-1,724 kPa) to rod tube and hold for a minimum of
2 minutes. Check rod hose/actuator connection for leakage.
(8) If required, check VBV actuation system per WP 1312 00.
(9) Release pressure on VBV hydraulic system. Disconnect hydraulic actuator unit
from VBV hose adapters.
(10) Remove VBV hose adapters. Remove seal gaskets. Inspect seal gaskets for
serviceability. Discard damaged seal gaskets.
(11) Install new or serviceable seal gasket, P/N J219P03, into HCU rod-end port.
Using washers and bolts, secure rod hose to HCU. Tighten bolts to
33-37 lb in. (3.8-4.1 N·m) of torque.
(12) Install new or serviceable seal gasket, P/N J219P04, into HCU head-end port.
Using washers and bolts, secure head hose to HCU. Tighten bolts to
33-37 lb in. (3.8-4.1 N·m) of torque.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
M. Slide drain adapter over coupling nuts and connect onto adapter port (figure 1).
Hand-tighten drain adapters.
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WP 1311 00
N. Leak-check drain adapters as follows:
WARNING
• Nitrogen, BB-N-411, can displace oxygen in enclosed
areas. Use in a well-ventilated area.
• When using compressed air for cleaning, cooling, or dry-
ing, do not exceed 30 psig. Wear eye protection and do
not direct compressed air at self or others.
(1) Connect a source of clean, dry, regulated shop air or nitrogen to drain line fitting
on drain adapter.
(2) Apply 50-55 psi (345-379 kPa) to drain adapter. Shut off pressure and monitor.
Pressure shall not drop off more than 10 psi (69 kPa) in 2 minutes.
(3) If pressure drop limit is exceeded, use soap solution to detect leak. Repair, as
required, and repeat leak check.
(4) Disconnect test equipment from drain adapter.
(5) Connect drain line to drain adapter. Tighten coupling nuts to 270-300 lb in.
(30.6-33.9 N·m) of torque.
O. If required, connect electrical connector to VBV actuator as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling back shell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Tighten connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
10
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NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required.
P. Using washers, bolts, and nuts, install access panels onto air collector per
WP 2310 00. Tighten bolts and nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
11/(12 Blank)
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WP 1312 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE BYPASS VALVE (VBV) SYSTEM CHECK
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 0
Alphabetical Index
Subject Page
Variable Bypass Valve (VBV) System Check............................................................................. 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1312 00
1. Introduction.
This work package contains instructions for checking the variable bypass valve (VBV) system.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No
Hydraulic Actuator Unit 1C3569G3
Tool Set, Rigging, VBV Doors 1C9353G02
Adapter Set, Pressure Test/Rig - VIGV, 1C9393G01
VBV, VSV
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Molybdenum Disulfide Lubricant MIL-L-25681
Cable, Safety 736L680G01
Wire, Safety R297P04
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal (Rod-End) J219P03 1
Gasket, Seal (Head-End) J219P04 1
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WP 1312 00
6. Variable Bypass Valve (VBV) System Check.
A. Remove air collector access panels. See figure 1.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and res-
piratory tract. Skin and eye protection is required. Avoid
repeated or prolonged contact. Use in a well-ventilated
area.
B. Remove bolts and washers that secure VBV head hose to hydraulic control unit
(HCU).
See figure 2. Remove seal gasket.
C. Install seal gasket, P/N J219P04, onto VBV hose adapter from adapter set, 1C9393.
Secure adapter to VBV head hose using washers and bolts. Tighten bolts to
33-37 lb in. (3.8-4.1 N•m) of torque.
D. Remove bolts and washers that secure VBV rod hose to HCU. Remove seal gasket.
E. Install seal gasket, P/N J219P03, onto VBV hose adapter from adapter set, 1C9393.
Secure adapter to VBV rod hose using washers and bolts. Tighten bolts to 33-37 lb in.
(3.8-4.1 N•m) of torque.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply can result in part damage.
F. Connect hydraulic actuator unit, 1C3569, to hose adapters. Tighten fittings to
135-150 lb in. (15.3-16.9 N•m) of torque.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
G. Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VBV system to the
full open and full closed positions several times. System shall operate smoothly
throughout entire range of travel in both directions.
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Figure 1. Air Collector Access Panels
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Figure 2. VBV Hose Locations
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NOTE
VBV position indication is read at indicator on control panel. Control
panel must be powered up to read VBV position indication.
H. Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VBV system to the
full closed position. Insert four rig pins, 1C9353. Rig pins shall insert freely through
unison ring and thread into the four threaded bosses at the 12:30, 2:00, 6:30, and 8:00
o'clock positions. See figure 3. VBV position indicator shall indicate 0 ± 1 percent
(full closed).
I. If VBV position indicator does not indicate 0 ± 1 percent (full closed), adjust the
rigging as follows (figure 4):
(1) Release hydraulic pressure from system.
(2) Loosen jamnut on each of the six rod-end bearing/actuator clevis linkages.
(3) Remove six nuts and bolts attaching rod-end bearing/actuator clevis linkages to
actuator rods.
Figure 3. VBV Door, Unison Ring, and Rig Pin Hole
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Figure 4. VBV Rigging
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
(4) Apply hydraulic pressure so that actuator rods are fully retracted (full closed).
(5) Turn rod-end bearing(s) in or out of the actuator clevis(es), as necessary, until
hole in rod-end bearing(s) aligns with hole in the clevis on actuator rod(s).
Tighten jamnut(s) finger-tight.
(6) Apply molybdenum disulfide lubricant onto threads of six bolts.
(7) Install six bolts and nuts that attach rod-end bearing/actuator clevis linkages to
actuator rods. Tighten nuts to 125 lb in. (14.1 N•m) of torque.
(8) Ensure that a 0.055-inch (1.40 mm) diameter wire will not pass through witness
hole in actuator devises. If necessary, turn rod-end bearing and clevis on actuator
rod to position rod-end bearing centered in actuator clevis.
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(9) Tighten jamnuts on rod-end bearing/actuator clevis linkages to 80 lb in. (9.0 N•m)
of torque. Safety cable or safety wire jamnuts to clevises.
J. Remove four rig pins. Release pressure on VBV hydraulic system.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
K. Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VBV system to the
full open position. VBV position indicator shall indicate 100 ± 1 percent (full open).
L. Release pressure on VBV hydraulic system.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply can result in part damage.
M. Disconnect hydraulic actuator unit from VBV hose adapters.
N. Remove VBV hose adapters. Remove seal gaskets. Inspect seal gaskets for
serviceability. Discard damaged seal gaskets.
O. Install new or serviceable seal gasket, P/N J219P03, onto HCU rod-end port. Secure
VBV rod hose to HCU using washers and bolts. Tighten bolts to 33-37 lb in.
(3.8-4.1 N•m) of torque.
P. Install new or serviceable seal gasket, P/N J219P04, onto HCU head-end port. Secure
VBV head hose to HCU using washers andbolts. Tighten bolts to 33-37 lb in.
(3.8-4.1 N•m) of torque.
Q. Using washers, bolts, and nuts, install air collector access panels. See figure 1. Tighten
bolts and nuts to 55-70 lb in. (6.3-7.9 N•m) of torque.
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WP 1313 00
5WP 1313 00
WORK PACKAGE
TECHNICAL PROCEDURES
BYPASS VALVE, BELLCRANK, AND
ACTUATING RING REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 16
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 15 ...... 4
16 Blank . . . . . . 4
Alphabetical Index
Subject Page
Bypass Valve, Bellcrank, and Actuating Ring Installation ......................................................... 7
Bypass Valve, Bellcrank, and Actuating Ring Removal............................................................. 3
Change 4 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1313 00
1. Introduction.
This work package contains instructions for removing and installing a bypass valve, bellcrank,
and actuating ring.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Hydraulic Actuator Unit 1C3569G3
Tool Set, Rigging, VBV Doors 1C9353G02
Adapter Set, Pressure Test/Rig - VIGV, 1C9393G01
VBV, VSV
Sling, Lift MSE-53
Bottle Jack Local Purchase
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
Molybdenum Disulfide Lubricant MIL-L-25681
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Sprayable Air Drying Lubricant GE Spec. A50TF192,
Class B
Loctite 271 or European Loctite 275 GE Spec. A15B41A9
(MIL-S-46163A,
Type I, Grade A)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal (Rod-End) J219P03 1
Gasket, Seal (Head-End) J219P04 1
2 Change 4
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6. Bypass Valve, Bellcrank, and Actuating Ring Removal.
A. Remove access panels from front frame air collector, as required, to gain access.
B. If required, remove lower section of air collector as follows (figure 1):
(1) Position bottle jack with protective block to support accessory gearbox.
(2) Remove screws that secure engine thrust mount frame seals. Remove seals.
1
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
(3) Using a 1-ton (907 kg) capacity overhead hoist, position lift sling above air
collector. Secure sling arms to air collector lower section. Take up slack on hoist
to support air collector lower section.
(4) Remove nuts, washers, and bolts that secure air collector lower section.
(5) Slowly lower sling while pulling lower section clear of engine.
(6) Repeat steps (3), (4), and (5) to remove remaining lower section.
C. Remove bypass valve (figure 2) and hinge assembly as follows:
(1) Remove nut, washers, and bolt that secure clevis rod-end bearing to valve.
(2) Remove bolts (Section A-A) and washers that secure hinge to front frame.
Remove valve with attached hinge.
(3) Remove nuts, washers, screws, and bushings that secure hinge to valve. Separate
hinge from valve.
(4) Repeat steps (1) through (3) to remove remaining 11 bypass valves.
2
D. Remove actuating ring and bellcranks (figure 3) as follows:
3
(1) Remove 12 bolts (View B) that secure bypass valve bellcrank to actuating ring.
(2) Remove six bolts that secure variable bypass valve (VBV) actuator bellcrank to
actuating ring.
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Figure1. Front Frame Air Collector
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Figure 2. Bypass Valve Replacement
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Figure 3. Actuating Ring and Bellcrank Removal
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NOTE
Bellcrank bearings are tack-welded to the frame.
E. Remove bolts (Section A-A), flat washers, thrust washers, sleeves, and washers that
secure 18 bellcranks onto bearing. Remove bellcranks from bearing.
NOTE
Actuating ring halves are a matched set.
F. Remove four bolts (View B) from connector plate (if present) at struts No. 2 and 5,
and remove actuating ring halves from front frame. Remove screw thread inserts.
G. Remove nut (figure 2, Detail C), bolt, and washer that secure clevis to bypass valve
bellcrank.
H. Loosen jamnut and remove rod-end bearing from clevis.
7. Bypass Valve, Bellcrank, and Actuating Ring Installation.
A. Assemble bypass valve (figure 2) to hinge as follows:
WARNING
Solid film lubricant is toxic to skin, eyes, and respiratory
tract. Skin, eye, and respiratory protection is required.
(1) Apply molybdenum disulfide lubricant onto threads of screws.
(2) Align hinge with bypass valve. Install bushings, flange outside, through valve
and hinge.
CAUTION
The newer configuration VBV doors are aluminum and require
longer screws to ensure engagement with the self-locking nuts. The
steel and aluminum VBV doors are interchangeable on the engine,
but screws are not interchangeable. Longer screws are required for
use with aluminum VBV doors, but may be used with steel VBV
doors. Use of shorter screws with aluminum VBV doors will result in
damage to the engine.
(3) Install two screws, washers, and nuts to secure hinge to bypass valve. Install
screw through bushing from outside, washers and nuts inside. Ensure longer
screws are used with aluminum VBV doors, P/N L56212G01, or engine damage
will occur. Refer to GEK 105060, Figure 4.
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(4) Tighten screws to 33-37 lb in. (3.8-4.2 N·m) of torque.
(5) Repeat steps (1) through (4) for remaining 11 bypass valve/hinge assemblies.
B. Determine valve position as follows (figure 4):
(1) Measure from aft center portion of valve bottom to seal retainer lip. Record as
dimension B.
4
(2) Subtract 0.050 inch (1.27 mm) from dimension B. Record difference as
dimension C.
(3) Measure bypass port rear face from inside outward. Using marking pen, mark rear
face at dimension C. DIM C ACTUAL:
C. Install bypass valve/hinge assembly (figure 2) onto front frame as follows:
WARNING
Solid film lubricant is toxic to skin, eyes, and respiratory
tract. Skin, eye, and respiratory protection is required.
(1) Apply sprayable lubricant to seal on bypass valve and mating surface of front
frame.
(2) Apply molybdenum disulfide onto bolt threads. Install bypass valve/hinge
assembly in opening on front frame.
(3) Secure bypass valve/hinge assembly onto front frame using two bolts and
washers.
(4) Tighten bolts to 100-130 lb in. (11.3-14.6 N·m) of torque.
(5) Repeat steps (1) through (4) for remaining 11 bypass valve/hinge assemblies.
D. Assemble bypass valve bellcrank and clevis assemblies as follows:
(1) Apply thin coating of molybdenum disulfide lubricant onto threads of rod-end
bearing.
(2) Thread jamnut onto rod-end bearing and install bearing to clevis. Thread bearing
into clevis approximately 0.375 inch (9.53 mm), until end of thread is flush with
underside of clevis. Tighten jamnut finger-tight.
(3) Apply thin coating of molybdenum disulfide lubricant onto threads of
bellcrank-to-clevis bolt.
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Figure 4. Bypass Valve Positioning
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(4) Align clevis with bellcrank angled leg and install bolt, washer, and nut. Install
washer under nut and bolthead on frame side of bellcrank.
(5) Tighten nut to 90-110 lb in. (10.2-12.4 N·m) of torque.
(6) Repeat steps (1) through (5) for remaining 11 bellcrank and clevis assemblies.
E. Install actuating ring (figure 3) onto front frame as follows:
(1) Adjust six VBV actuators as follows:
(a) Remove protective caps from VBV actuators.
(b) Pull actuator rod to full extended position.
(c) Push rod into actuator to full retracted position until contact is made.
(d) Install protective caps in VBV actuator ports.
CAUTION
Variable bypass valve actuator rods must remain in the full
retracted position for successful VBV components installation.
Adjust rod-end bearing length to align with actuator rod end;
do not extend VBV actuator rods to align with rod-end bear-
ings.
(2) Apply molybdenum disulfide lubricant to threads of four bolts (View B).
(3) Position actuating ring halves around front frame so halves connect at
approximately 2:00 and 8:00 o’clock positions (over struts No. 2 and 5).
NOTE
There are two configurations of actuating rings. Early configuration
has connector plates. Latest configuration does not.
(4) Secure actuating ring halves together using connector plates and bolts. Longest
bolt goes through center hole of each connector plate. Tighten bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
F. Install 12 bypass valve bellcrank assemblies (figure 3) as follows:
(1) Apply molybdenum disulfide lubricant to threads of 12 bolts that secure
bellcranks onto bearing.
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(2) Install washer (Section A-A) and sleeve onto bearing. Install bellcrank assembly.
Install thrust washer on top of bellcrank.
(3) Secure bellcrank assembly onto bearing with washer and bolt. Tighten bolts to
55-70 lb in. (6.2-7.9 N·m) of torque.
(4) Repeat steps (1) through (3) for remaining 11 bellcrank assemblies.
(5) Check that each bellcrank assembly operates freely, using finger force only.
G. Assemble 18 bellcranks to actuating ring as follows:
NOTE
There are two configurations of actuating rings. Early configuration
has slots at the bellcrank locations. Later configuration is U-shaped.
(1) Align actuating ring (figure 2, View B) to front frame with four locating pins,
1C9353P02. Insert locating pins through actuating ring and thread into front frame
at 4:00, 7:00, 10:00, and 12:30 o’clock positions. Tighten locating pins hand-tight;
do not force the assembly. This is the bypass valve rig position.
(2) Rotate bellcranks until straight leg engages into actuation ring.
(3) Apply Loctite 271 to threads of 18 bolts (figure 3, View B) that secure bellcranks to
actuation ring. Align bellcranks with holes in ring. Install bolts through ring and
bellcrank. Tighten bolts to 225 lb in. (25.4 N·m) of torque.
H. Assemble rod-end bearings (figure 2) to bypass valves as follows:
(1) Apply molybdenum disulfide lubricant to threads of 12 bolts that secure rod-end
bearings to bypass valves.
(2) With actuator rods fully retracted and four locating pins installed, align rod-end
bearing to bypass valve clevis.
(3) Thread rod-end bearing to bellcrank clevis to align boltholes. Adjust so bolt can be
installed with center of bypass valve aft lip protruding into air flow path.
(4) Adjust rod-end bearings at each of 12 bellcranks to obtain required bypass valve
alignment. Check that there is full thread engagement of bearing into clevis,
approximately 0.375 inch (9.53 mm). Do not torque jamnuts at this time.
(5) Install bolt, washers, and nut to hold clevis to rod-end bearing. Bolthead is on right
side of valve, aft looking forward. Washer is under bolt and nut. See View B.
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(6) Tighten 12 nuts at valve and clevis pivot point to 55-70 lb in. (6.2-7.9 N·m) of
torque. Safety-cable or lockwire nuts.
(7) Position 12 rod-end bearings centered in clevises. This will prevent premature
failure of rod-end bearings.
(8) Tighten 12 rod-end bearing jamnuts (figure 2, Detail C) to 55-70 lb in.
(6.2-7.9 N·m) of torque. Safety-cable or lockwire jamnuts.
(9) Remove four locating pins, 1C9353P02, from actuating ring.
I. Final test VBV hydraulic system as follows:
(1) Remove bolts and washers that secure VBV head hose onto hydraulic control unit
(HCU). Remove seal gasket (figure 5).
5
(2) Install seal gasket, PN J219P04, onto VBV hose adapter from adapter set,
1C9393. Using washers and bolts, secure adapter onto head hose. Tighten bolts to
33-37 lb in. (3.8-4.1 N·m) of torque.
(3) Remove bolts and washers that secure VBV rod hose onto HCU. Remove seal
gasket.
(4) Install seal gasket, PN J219P03, onto VBV hose adapter from adapter set,
1C9393. Using washers and bolts, secure adapter onto rod hose. Tighten bolts to
33-37 lb in. (3.8-4.1 N·m) of torque.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
(5) Connect hydraulic actuator unit, 1C3569, onto hose adapters. Tighten fittings to
135-150 lb in. (15.3-16.9 N·m) of torque.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
(6) Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VBV system to
full open and full closed positions several times. System shall operate smoothly
throughout entire range of travel in both directions.
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Figure 5. VBV Hose Locations
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(7) Apply 200-250 psi (1379-1724 kPa) system pressure to actuate VBV system to
full closed position. Variable bypass valve seal retainer lip shall align with mark
on inside lip of bleed port rear face.
(8) Release pressure on VBV hydraulic system.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
(9) Disconnect hydraulic actuator unit from VBV hose adapter set.
(10) Remove VBV hose adapters (figure 5). Remove seal gaskets. Inspect seal gaskets
for serviceability. Discard damaged seal gasket.
(11) Install new or serviceable seal gasket, PN J219P03, onto HCU rod port.
Using washers and bolts, secure rod hose to HCU. Tighten bolts to 33-37 lb in.
(3.8-4.1 N·m) of torque.
(12) Install new or serviceable seal gasket, PN J219P04, onto HCU head port. Using
washers and bolts, secure head hose to HCU. Tighten bolts to 33-37 lb in.
(3.8-4.1 N·m) of torque.
J. If removed, install lower section of air collector as follows (figure 1):
(1) Position lower section under air collector.
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
(2) Using a 1-ton (907 kg) capacity overhead hoist, position lift sling above air
collector. Secure sling arms to lower section.
(3) Slowly raise lower section into position.
(4) Apply molybdenum disulfide lubricant onto threads of bolts.
(5) Install bolts and nuts that secure lower section onto front frame forward flange.
Boltheads face aft.
(6) Install bolts that secure lower section onto front frame aft flange.
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(7) Install bolts and nuts that secure flanges. Boltheads face up or outboard.
(8) Tighten flange nuts to 480-570 lb in. (54.3-64.4 N·m) of torque.
(9) Remove sling.
(10) Tighten nuts that secure lower section onto front frame forward flange to
55-70 lb in. (6.3-7.9 N·m) of torque.
(11) Tighten bolts that secure lower section onto front frame aft flange to
55-70 lb in. (6.3-7.9 N·m) of torque.
(12) Repeat steps (1) through (11) for remaining lower section.
(13) Install thrust mount frame seals and secure with screws.
(14) Tighten screws to 55-70 lb in. (6.3-7.9 N·m) of torque.
K. Using washers, bolts, and nuts, install access panels onto air collector. Tighten bolts
and nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
L. Remove bottle jack and protective block.
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5WP 1410 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE STATOR VANE (VSV) ACTUATOR
COMPONENTS REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 16
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 16 ...... 2
Alphabetical Index
Subject Page
Variable Stator Vane Actuator Installation .................................................................................. 7
Variable Stator Vane Actuator Length Preset Adjustment Using Fixture, 1C9403..................... 13
Variable Stator Vane Actuator Lever Installation ........................................................................ 15
Variable Stator Vane Actuator Lever Removal............................................................................ 14
Variable Stator Vane Actuator Ring Installation.......................................................................... 16
Variable Stator Vane Actuator Ring Removal ............................................................................. 16
Variable Stator Vane Actuator Removal ...................................................................................... 3
Variable Stator Vane Connecting Link Installation ..................................................................... 16
Variable Stator Vane Connecting Link Removal......................................................................... 16
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1. Introduction.
This work package contains instructions for removing and installing the variable stator vane
(VSV) actuation components.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Stator Vane (VSV) Rigging WP 1411 00
High Pressure Compressor (HPC) Upper and Lower Stator WP 2411 00
Case Replacement
High Pressure Compressor (HPC) Stator Vanes Replacement WP 2412 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Hydraulic Actuator Unit 1C3569G3
Adapter Set, Pressure Test/Rig - VIGV, 1C9393G01
VBV, VSV
Fixture, Check VSV/VIGV Actuators 1C9403G01
4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
Lubricating Oil MIL-L-23699
Marking Pen Sharpie T.E.C.
(Black or Blue)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Silicone Rubber Adhesive GE Spec A15F6B56
(RTV 106)
Soap Solution Local Purchase
Thread Lubricant GP 460
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P904 2
Packing, Preformed 9365M41P117 2
Packing, Preformed 9365M41P122 2
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6. Variable Stator Vane Actuator Removal.
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
A. Tag and disconnect electrical connector from VSV actuator.
NOTE
Ensure that lube oil supply is shut off before disconnecting tubing.
B. Disconnect tubing as follows (figure 1):
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(1) Position a waste fluid container beneath VSV actuator. Disconnect drain line
from drain adapter.
(2) Disconnect drain adapter from VSV actuator. Slide drain adapter away from
VSV actuator ports to expose coupling nut.
1
CAUTION
Ensure connecting fitting is restrained when loosening
coupling nut. Failure to comply may result in part damage.
(3) Disconnect coupling nut from VSV actuator fitting.
(4) Remove and discard preformed packing from drain adapters.
C. Remove bolts that secure actuator bracket to front frame. See figure 2.
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Figure 1. VSV Actuator Tubing
CAUTION
Do not change adjustment of actuator rod end. Any movement
or adjustment requires that paragraph 8 be performed and
VSV actuation system rigging be checked.
D. Remove nut and bolt that secure VSV actuator to bracket. Separate bracket from VSV
actuator.
E. Rotate guide 90 degrees. Remove guide and VSV actuator from actuation lever.
F. Remove fitting from VSV actuator. Remove and discard preformed packings.
See figure 1.
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2
Figure 2. VSV Actuation Components (Sheet 1 of 2)
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1
Figure 2. VSV Actuation Components (Sheet 2 of 2)
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7. Variable Stator Vane Actuator Installation.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust venti-
lation - if not available, use an approved respirator.
NOTE
If installing a new actuator, or in the event actuator rod end adjust-
ment is disturbed during removal/installation, perform paragraph 8
A. Lubricate preformed packings, P/N J221P904 and P/N 9365M41P122, with
lubricating oil, and install into groove of fitting. See figure 1.
B. Install fitting into VSV actuator. Tighten fitting to 135-150 lb in. (15.3-16.9 N·m) of
torque.
CAUTION
Do not change adjustment of actuator rod end. Any movement
or adjustment requires that paragraph 8 be performed and
VSV actuation system rigging be checked.
C. Position VSV actuator rod end over forward end of actuation lever. See figure 2.
D. Install guide onto end of lever. AFT mark on guide faces aft. Rotate guide 90 degrees.
E. Apply thread lubricant onto threads of actuator retaining bolt and actuator bracket
retaining bolts.
F. Slide VSV actuator so that guide fits into channel of bracket. Using bolt and nut,
secure VSV actuator to bracket. Bolthead faces forward. Tighten nut to 120-150 lb in.
(13.6-16.9 N·m) of torque.
G. Using bolts, secure actuator bracket onto front frame. Tighten bolts per figure 3 and
safety-wire.
3
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Figure 3. VSV Actuator Bracket Installation
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WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
H. Lubricate preformed packing, P/N 9365M41P117, with lubricating oil and install into
drain adapter. See figure 1.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
I. Connect tubing coupling nut to VSV actuator fittings. Tighten coupling nut to
270-300 lb in. (30.6-33.9 N·m) of torque.
J. Leak-check head- and rod-end fittings as follows (figure 4):
4
CAUTION
Use hydraulic actuator unit, 1C3569, with engines that use
lubricating oil, MIL-L-23699. Do not intermix lubricating oil,
MIL-L-7808 and MIL-L-23699, or damage will occur.
(1) Install reducers from adapter set, 1C9393, onto hydraulic actuator unit, 1C3569.
Tighten reducers to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Position waste fluid container under hydraulic control unit (HCU).
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Figure 4. Hydraulic Actuator Unit, 1C3569
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WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do
not inhale, ingest, or let this material touch you. Irritant.
Personal protective equipment required. Use mechanical
exhaust ventilation - if not available, use an approved respi-
rator.
CAUTION
Ensure connecting fitting is restrained when loosening or
tightening coupling nut. Failure to comply may result in part
damage.
(3) Disconnect VSV head tube from HCU. Install head tube onto -4 to -10 reducer.
Tighten coupling nut to 650-770 lb in. (73.5-87.0 N·m) of torque.
(4) Disconnect VSV rod tube from HCU. Install rod tube onto -4 to -8 reducer.
Tighten coupling nut to 450-550 lb in. (50.9-62.1 N·m) of torque.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
(5) Apply 200-250 psi (1,379-1,724 kPa) to head tube and hold for a minimum of
2 minutes. Check head tube/actuator connection for leakage.
(6) Apply 200-250 psi (1,379-1,724 kPa) to rod tube and hold for a minimum of
2 minutes. Check rod tube/actuator connection for leakage.
(7) If required, check VSV system rigging per WP 1411 00.
(8) Disconnect hydraulic actuator unit, 1C3569. Remove reducers.
(9) Connect head tube to HCU. Tighten coupling nut to 650-770 lb in.
(73.5-87.0 N·m) of torque.
(10) Connect rod tube to HCU. Tighten coupling nut to 450-550 lb in. (50.9-62.1 N·m)
of torque.
K. Slide drain adapter over coupling nut and connect to VSV actuator port. See figure 1.
Hand-tighten drain adapters.
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L. Leak-check drain adapters as follows:
WARNING
• Nitrogen, BB-N-411, can displace oxygen in enclosed
areas. Use in a well-ventilated area.
• When using compressed air for cleaning, cooling, or
drying, do not exceed 30 psig. Wear eye protection and
do not direct compressed air at self or others.
(1) Connect a source of clean, dry, regulated shop air or nitrogen to drain line fitting
on drain adapter.
(2) Apply 50-55 psi (345-379 kPa) to drain adapter. Shut off pressure and monitor.
Pressure shall not drop off more than 10 psi (69 kPa) in 2 minutes.
(3) If pressure drop limit is exceeded, use soap solution to detect leak. Repair as
required and repeat leak check.
(4) Disconnect test equipment from drain adapter.
(5) Connect drain line to drain adapter. Tighten coupling nut to 270-300 lb in.
(30.6-33.9 N·m) of torque.
M. Connect electrical connector to VSV actuator as follows:
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Tighten connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no move-
ment with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required.
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8. Variable Stator Vane Actuator Length Preset Adjustment Using Fixture, 1C9403.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
CAUTION
• Maintain 250.0 psi (1,724 kPa) on actuator, at the fully
extended position, when adjusting rod end.
• Use hydraulic actuator unit, 1C3569, with engines that use
lubri-cating oil, MIL-L-23699. Do not intermix lubricating
oil,MIL-L-7808 and MIL-L-23699, or damage will occur.
NOTE
This procedure is to be performed before installing a new actuator or
in the event actuator rod end adjustment is disturbed during
removal/installation.
A. Connect hydraulic actuator unit, 1C3569, to actuator. Supply 250.0 psi (1,724 kPa) to
extend actuator to fully extended position. Maintain pressure throughout adjustment
procedure.
5
B. Loosen jamnut that secures actuator rod end.
C. Adjust rod end so that actuator slides freely onto fixture, 1C9403. See figure 5.
D. Tighten jamnut to secure rod end. Safety-wire jamnut.
E. Release pressure and remove hydraulic actuator unit, 1C3569.
F. Perform VSV rigging per WP 1411 00 before operating engine.
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Figure 5. Actuator Length Preset Using Fixture, 1C9403
9. Variable Stator Vane Actuator Lever Removal.
A. Remove VSV actuator per paragraph 6
B. Remove bolts, washers, bushings (stages 3-5), and nuts that secure clevis assemblies to
VSV connecting links. See figure 2.
C. Remove nut, washer, and spacer that secure actuation lever to aft mount and remove
lever.
D. Mark stage number on each clevis assembly with marking pen.
E. Remove nuts and bolts that secure clevis assemblies to actuation lever.
F. Separate seal boots and slot-loaded bearings from actuation lever.
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10. Variable Stator Vane Actuator Lever Installation.
A. Install slot-loaded bearings into actuation lever (figure 2). Install seal boots over
bearings.
B. Apply thread lubricant to threads of clevis bolts.
C. Secure clevis assemblies to actuation lever using nuts and bolts (boltheads next to
engine). Tighten nuts to 62-68 lb in. (7.0-7.7 N·m) of torque.
D. Install spacer and actuation lever over aft mount stud.
E. Apply thread lubricant to stud threads and install washer and nut. Tighten nut to
190-230 lb in. (21.5-25.9 N·m) of torque.
E.A Apply thread lubricant to threads of rod-end bearing to connecting link bolts.
F. Align clevis rod-end bearings with connecting links and secure with bolts, washers,
and nuts. Before Service Bulletin LM6000-IND-0203, boltheads face forward. After
SB LM6000-IND-0203, boltheads face forward at stage IGV through stage 4 and bolt-
head faces aft at stage 5. One washer is under bolthead and one washer is under nut.
Before Service Bulletin LM6000-IND-0203, bushing is between aft side of rod-end
bearing and connecting link on stages 3-5. After SB LM6000-IND-0203, bushing is
between aft side of rod-end bearing and connecting link on stages 3 and 4, and bushing
is between forward side of bearing and connecting link on stage 5.
G. Tighten rod-end bearing to connecting link nuts to 62-68 lb in. (7.0-7.7 N·m) of torque.
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
H. Using isopropyl alcohol, clean lever aft mount and spacer.
WARNING
Vapor from uncured sealant is flammable and toxic to skin,
eyes, and respiratory tract. Avoid contact with skin and
eyes. Use in a well-ventilated area.
I. Apply silicone rubber adhesive over exposed joint between lever, spacer, and aft
mount. Allow adhesive to cure for 8 hours minimum before engine operation.
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11. Variable Stator Vane Connecting Link Removal.
A. Remove VSV actuation lever per paragraph 9.
CAUTION
Do not change adjustment of actuator rod end. Any movement
or adjustment requires that paragraph 8 of this work package
be performed and VSV actuator system rigging be checked.
B. Remove VSV connecting links per WP 2411 00.
12. Variable Stator Vane Connecting Link Installation.
A. Install VSV connecting links per WP 2411 00.
B. Install VSV actuation lever per paragraph 10
13. Variable Stator Vane Actuator Ring Removal.
A. Remove VSV actuation lever per paragraph 9.
CAUTION
Do not change adjustment of actuator rod end. Any movement
or adjustment requires that paragraph 8 of this work package
be performed and VSV actuator system rigging be checked.
B. Remove VSV connecting links per WP 2411 00.
C. Remove VSV actuation ring per WP 2412 00.
14. Variable Stator Vane Actuator Ring Installation.
A. Install VSV actuation ring per WP 2412 00.
B. Install VSV connecting links per WP 2411 00.
C. Install VSV actuation lever per paragraph 10
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5WP 1411 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE STATOR VANE (VSV) RIGGING
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 22
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 21 ...... 5
22 Blank . . . . . . 5
Alphabetical Index
Subject Page
Hydraulic Actuator Unit, 1C3569, Installation........................................................................... 3
Hydraulic Actuator Unit, 1C3569, Removal .............................................................................. 21
Variable Stator Vane Actuation Ring Spacer Clearance Adjustment.......................................... 3
Variable Stator Vane Actuator Full Travel Verification .............................................................. 20
Variable Stator Vane System Rigging (1C9365)......................................................................... 10
Variable Stator Vane System Rigging (2C6925)......................................................................... 6
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1. Introduction.
This work package contains instructions for rigging the variable stator vane (VSV) system.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Hydraulic Actuator Unit 1C3569G3
Protractor Assy, Electronic, Portable - VSV 1C9365G01
Adapter Set, Pressure Test/Rig - VIGV, 1C9393G01
VBV, VSV
Gage Set, VSV Clevis 2C6925G03
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GP 460
5. Expendable Material.
None required.
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6. Hydraulic Actuator Unit, 1C3569, Installation.
See figure 1.
A. Position waste fluid container beneath hydraulic control unit (HCU).
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Per-
sonal protective equipment required. Use mechanical exhaust
ventilation - if not available, use an approved respirator.
CAUTION
• Ensure connecting fitting is restrained when loosening or tightening
coupling nut. Failure to comply may result in part damage.
• Use hydraulic actuator unit, 1C3569, with engines that use
lubricating oil, MIL-L-23699. Do not intermix lubricating oil,
MIL-L-7808 and MIL-L-23699, or damage will occur.
B. Install reducers, from adapter set, 1C9393, onto hydraulic actuator unit. Tighten
reducer to 135-150 lb in. (15.3-16.9 N·m) of torque.
C. Disconnect head tube from HCU. Install head tube onto -4 to -10 reducer.
Tighten tube to 650-770 lb in. (73.5-87.0 N·m) of torque.
D. Disconnect rod tube from HCU. Install rod tube onto -4 to -8 reducer. Tighten
tube to 450-550 lb in. (50.9-62.1 N·m) of torque.
7. Variable Stator Vane Actuation Ring Spacer Clearance Adjustment.
CAUTION
Prior to performing this work package, ensure the following
conditions exist:
• VSV vane arms are installed in actuation rings.
• Actuation rings are secured to bridge connectors.
• Actuating arm levers are installed and secured properly.
• VSV actuators are installed and secured properly.
A. Position stator vanes to full open position (VSV actuator rods fully extended) by
applying hydraulic pressure.
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1
Figure 1. Hydraulic Actuator Unit, 1C3569
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NOTE
All eight spacers per stage shall be adjusted at the same time.
B. Adjust actuation ring spacers. See figure 2.
C. Tighten locknuts to 60-70 lb in. (6.8-7.9 N·m) of torque.
D. Measure clearance between spacer and high pressure compressor (HPC) case
(dimension M). Clearance shall be within limits of figure 2.
Figure 2. VSV Actuation Ring Spacer Clearance
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NOTE
An alternate method of rigging VSV system using electronic
protractor, 1C9365, is provided in paragraph 9.
8. Variable Stator Vane System Rigging (2C6925).
A. Before Service Bulletin LM6000-IND-0203, preset length of clevis assemblies as fol-
lows (figure 3):
CAUTION
Ensure stage number is marked on each clevis assembly.
Improper location of clevis assemblies will cause unpredictable
engine operation.
(1) Using marking pen, mark stage number on clevis assembly.
NOTE
Deleted.
(2) Deleted.
(3) Install clevis assembly into VSV clevis gage set, 2C6925.
(4) If necessary, loosen jamnut and adjust clevis assembly length to appropriate value
as specified in figure 3.
NOTE
Rod end adjustment must be equal within one-half thread on
each matched stage (2) clevis assembly.
(5) Tighten jamnut to 60-70 lb in. (6.8-7.9 N·m) of torque. Safety-wire jamnut.
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3
Figure 3. Preset Length of Clevis Assemblies Using Gage Set, 2C6925
B. After Service Bulletin LM6000-IND-0203, preset length of clevis assemblies as follows
(figure 3):
CAUTION
Ensure stage number is marked on each clevis assembly, improper
location of clevis assemblies will cause unpredictable engine
operation.
(1) Using marking pen, mark stage number on clevis assembly.
NOTE
After Service Bulletin LM6000-IND-0203, stage 5 clevis is manufac-
tured with a fixed length and does not require length adjustment per
preset rigging method.
(2) Install each stage IGV through stage 4 clevis assembly into VSV clevis gage set,
2C6925, one at a time.
(3) If necessary, loosen jamnut and adjust clevis assembly length to appropiate value as
specified in figure 3.
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NOTE
Rod end adjustment must be equal within one-half thread on
each matched stage (2) clevis assembly.
(4) Tighten jamnut to 60-70 lb in. (6.8-7.9 N·m) of torque. Safety-wire jamnut.
NOTE
After Service Bulletin LM6000-IND-0203, stage 5 clevis assem-
bly length is not adjustable.
(5) If required, confirm length of stage 5 clevis assembly as follows:
NOTE
Some 2C6925 tools may require modification to allow sufficient
travel to measure the length of stage 5 clevis assembly.
(a) Install stage 5 clevis assembly into VSV clevis gage set, 2C6925.
(b) Confirm stage 5 clevis length as specified in figure 3.
CAUTION
Ensure clevis assemblies are installed at the proper locations.
Failure to comply may cause unpredictable engine operation.
NOTE
Maintain 250 psig (1,724 kPa) pressure at head-end of actuators
while installing IGV through stage 5 clevises.
C. Install inlet guide vane (IGV) and stages 1 and 2 clevis assemblies as follows
(figure 4):
CAUTION
Jamnut safety wire shall not be broken when installing clevis
assemblies on actuating arm lever or bridge connector.
(1) Apply thread lubricant to threads of clevis bolts and rod end to bridge connector
bolts.
(2) Using bolt and nut, secure clevis (detail A) onto actuating arm lever, bolthead
facing inboard. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
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(3) Using bolt, washers, and nut, secure rod end to bridge connector, bolthead facing
forward. One washer goes under bolthead, and one washer goes under nut.
Tighten nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
D. Before Service Bulletin LM6000-IND-0203, install stage 3 through stage 5 clevis
assemblies as follows (figure 4):
(1) Apply thread lubricant to threads of clevis bolts and rod end to bridge connector
bolts.
(2) Using bolt and nut, secure clevis (detail B) to actuating arm lever, bolthead faces
inboard. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
(3) Using bolt, washers, bushing, and nut, secure rod end to bridge connector,
bolthead facing forward. Bushing goes between aft face of rod end and bridge
connector. One washer goes under bolthead, and one washer goes under nut.
Tighten nut to 62-68 lb in. (7.0-7.7 N·m) above run-on torque.
E. After Service Bulletin LM6000-IND-0203, install stage 3 through stage 5 clevis
assemblies as follows (figure 4A):
(1) For stage 3 and 4 clevis assemblies (detail A), proceed as follows:
(a) Apply thread lubricant to threads of clevis bolts and rod end to bridge connec-
tor bolts.
(b) Using bolt and nut, secure clevis to actuating arm lever, bolthead faces
inboard. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
(c) Using bolt, washers, bushing, and nut, secure rod end to bridge connector,
bolthead facing forward. Bushing goes between aft face of rod-end and
bridge connector. One washer goes under bolthead, and one washer goes
under nut. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) above run-on torque.
(2) For stage 5 clevis assembly (detail B), proceed as follows:
(a) Apply thread lubricant to threads of clevis bolt and bearing end to bridge con-
nector bolt.
(b) Using bolt and nut, secure clevis to actuating arm lever, bolthead faces
inboard. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
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(c) Using bolt, washers, bushing, and nut, secure bearing end to bridge connec-
tor, bolthead facing aft. Bushing goes between forward face of bearing end
and bridge connector. One washer goes under bolthead, and one washer goes
under nut. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) above run-on torque.
F. Verify full travel of VSV actuator per paragraph 10.
9. Variable Stator Vane System Rigging (1C9365).
CAUTION
Ensure clevis assemblies are installed at the proper locations.
Failure to comply may cause unpredictable engine operation.
NOTE
After Service Bulletin LM6000-IND-0203, stage 5 clevis assem-
bly is manufactured in one piece and does not require assembly.
A. Assemble clevis assemblies per figure 4. Do not tighten jamnuts at this time.
NOTE
Maintain 250 psig (1,724 kPa) pressure at head-end of actuators
while installing IGV through stage 5 clevises.
B. Install stage IGV through stage 2 clevis assemblies as follows (figure 4):
(1) Apply thread lubricant to threads of clevis bolts and rod end to bridge connector
bolts.
(2) Using bolt and nut, secure clevis (detail A) onto actuating arm lever, bolthead
facing inboard. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
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(3) Adjust clevis length to correct any mismatch of rod-ends and connectors.
1
(4) Using bolt, washers, and nut, secure rod end onto bridge connector, bolthead
facing forward. One washer under bolthead, and one washer under nut. Tighten
nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
C. Before Service Bulletin LM6000-IND-0203, install stage 3 through stage 5 clevis
assemblies as follows (figure 4):
(1) Apply thread lubricant to threads of clevis bolts and rod end to bridge connector
bolts.
(2) Using bolt and nut, secure clevis (detail B) to actuating arm lever, bolthead faces
inboard. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
(3) Adjust clevis length to correct any mismatch of rod-ends and connectors.
(4) Using bolt, washers, bushings, and nut, secure rod end onto bridge connector,
bolthead facing forward. Bushing goes between aft face of rod end and bridge
connector. One washer goes under bolthead, and one washer goes under nut.
Tighten nut to 62-68 lb in. (7.0-7.7 N·m) above run-on torque.
D. After Service Bulletin LM6000-IND-0203, install stage 3 through stage 5 clevis
assemblies as follows (figure 4A):
(1) For stage 3 and stage 4 clevis assemblies (detail A), proceed as follows:
(a) Apply thread lubricant to threads of clevis bolts and rod end to bridge con-
nector bolts.
(b) Using bolt and nut, secure clevis to actuating arm lever, bolthead faces
inboard. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
(c) Using bolt, washers, bushing, and nut, secure rod end to bridge connector,
bolthead facing forward. Bushing goes between aft face of rod-end and
bridge connector. One washer goes under bolthead, and one washer goes
under nut. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) above run-on torque.
(2) For stage 5 clevis assembly (detail B), proceed as follows:
(a) Apply thread lubricant to threads of clevis bolt and bearing end to bridge
connector bolt.
(b) Using bolt and nut, secure clevis to actuating arm lever, bolthead faces
inboard. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) of torque.
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(c) Using bolt, washers, bushing, and nut, secure bearing end to bridge connec-
tor, bolthead facing aft. Bushing goes between forward face of bearing end
and bridge connector. One washer goes under bolthead, and one washer goes
under nut. Tighten nut to 62-68 lb in. (7.0-7.7 N·m) above run-on torque.
E. Verify full travel of VSV actuator per paragraph 10.
F. Calibrate portable electronic protractor, 1C9365, to set master as follows (figure 5):
(1) Set 110v/60Hz, 230v/50Hz switch on back panel to proper setting for power
supply being used.
NOTE
P38 encoders should remain connected to readout unit to
ensure pre-rig check accuracy.
(2) Install encoder on set master ensuring tangs are engaged. Position locator arm at
zero degree. Install alignment pin through locator arm into zero degree hole of set
master.
(3) Connect encoder to digital position readout unit.
(4) Power up readout unit and allow to warm up for 15 minutes. When unit is
powered up, display will show P-UP. Press any R key to clear display.
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Figure 4. Vane Actuator Lever Assembly Before Service Bulletin LM6000-IND-0203
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Figure 4A. Vane Actuator Lever Assembly After Service Bulletin LM6000-IND-0203
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Figure 5. Portable VSV Electronic Protractor Tool Set, 1C9365
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NOTE
Ensure locator arm is in zero degree position before pressing
reset button.
(1) Move locator arm to zero position. Press reset button to set readout counter to
zero.
CAUTION
• Do not make any mechanical adjustments to encoder or
locator arm. Move arm slowly; rapid movement will cause
inaccurate readings. Operate one complete cycle between
readouts.
• Always pass through zero degree on set master when
checking angles. Inaccurate readings will result if not
actuated through zero from either + or - readings.
(2) Move locator arm to each degree hole in set master and check readout of counter.
Readings shall be within 0.2 degree of degree mark on set master. If readings
cannot be met within 0.2 degree, check for proper setup and security of plugs in
receptacle. Replace encoder or digital position readout unit as required.
(3) Return to zero hole in set master. Zero hole shall give zero reading after other
settings have been checked.
(4) Repeat steps (1) through (7) for remaining encoders.
G. Install P38 encoders on stage IGV through stage 2 vane stems as follows:
NOTE
• Refer to figure 6 for tool part numbers.
• Vane angles shall be measured from the vane positions listed on
figure 7, table 1. When adequate thread engagement cannot be
obtained (less than two threads), an alternate vane location, one
vane position either side of the locations listed in figure 7, table
1, may be used. Vane positions are numbered from the 9 o'clock
position (aft looking forward).
(1) Install post locators onto four vane stems as listed in figure 7, table 1. Tighten
post locator to 5-10 lb in. (0.6-1.1 N·m) of torque. See figure 6.
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Figure 6. Installation of P38 Encoders on Stage IGV Through Stage 5
3
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Figure 7. Encoder Mounting Locations and VSV Angles
(2) Install tang adapters over four post locators and engage adapter tangs in vane
arms. Scribe lines on tang adapters must face aft.
(3) Install arm locator onto second vane in either direction from the four vane
positions listed in figure 7, table 1.
(4) Install encoder over post locator. Engage slots in encoder with tangs of tang
adapter. Simultaneously, engage encoder arm with pin on arm locator.
(5) Measure stator vane angles per step I.
H. Install encoders on stages 3 through 5 vanes as follows (figure 6 and 7):
CAUTION
Use safety wire to ensure stator vane does not drop into stator
case when retaining nut is removed.
(1) Remove stator vane arm retaining nuts at locations where encoders will be
installed.
(2) Secure stator vane arm with nut. Tighten nut finger-tight.
(3) Install tang adapter over vane arm. Tighten setscrew to 55-70 lb in. (6.3-7.9 N·m)
of torque.
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(4) Install post locator and arm locator.
(5) Install encoder over post locator. Engage slot in encoder with tang of tang adapter.
Simultaneously, engage arm of encoder with arm locator pin.
(6) Measure stator vane angles per step I.
I. Measure stator vane angles as follows:
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
(1) Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VSV system to
full open and full closed positions several times. System shall operate smoothly
through entire range of travel in both directions.
NOTE
After Service Bulletin LM6000-IND-0203, stage 5 clevis is
manufactured in one piece and has no pushrod.
(2) Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VSV system to
full closed position. Pushrods shall be positioned for maximum clearance to
actuation rings and actuator lever arms. Record average of encoder readouts. The
average reading shall be between upper and lower limits listed in figure 7, table 2.
(3) Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VSV system to
full open position. Pushrods shall be positioned for maximum clearance to actua-
tion rings and actuator lever arms. Record average of encoder readouts. The aver-
age reading shall be between upper and lower limits listed on figure 7, table 2.
NOTE
• Rod end adjustment must be equal within one-half thread on
both sides of the engine.
• After Service Bulletin LM6000-IND-0203, stage 5 clevis is
manufactured with a fixed length and does not require
length adjustment.
(4) Adjust rod ends to obtain required angles at both open and closed positions.
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(5) Check clevis assemblies for proper engagement of rod end bearing threads by
attempting to insert No. 56 drill (0.55 inch [1.4 mm] diameter) through witness
hole at each end of clevis assembly. Drill shall not pass through.
(6) Tighten jamnuts to 60-70 lb in. (6.8-7.9 N·m) of torque. Safety-wire jamnuts.
CAUTION
Ensure stator vane does not drop into stator case when retaining
nut is removed.
(7) Remove encoders, post locators, tang adapter, arm locator, and retaining nut.
Install stator vane arm retaining nuts. Replace any nut when run-on torque falls
below 5 lb in. (0.6 N·m) or exceeds 40 lb in. (4.5 N·m) of torque. Tighten nuts to
85-95 lb in. (9.7-10.7 N·m) of torque.
J. Verify full travel of VSV actuator per paragraph 10.
10. Variable Stator Vane Actuator Full Travel Verification.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
A. Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VSV system to full
open and full closed positions several times. System shall operate smoothly through
entire range of travel in both directions.
NOTE
VSV position indication is read at indicator on control panel.
Control panel must be powered up to read VSV position indication.
B. Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VSV system to full
closed position. VSV position indicator shall indicate 0 ± 1 percent.
C. Apply 200-250 psi (1,379-1,724 kPa) system pressure to actuate VSV system to full
open position. VSV position indicator shall indicate 100 ± 1 percent.
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11. Hydraulic Actuator Unit, 1C3569, Removal.
See figure 1.
CAUTION
Ensure connecting fitting is restrained when loosening or
tightening coupling nut. Failure to comply may result in part
damage.
A. Disconnect hydraulic actuator unit. Remove reducers.
B. Connect head tube to HCU. Tighten coupling nut to 650-770 lb in. (73.5-87.0 N·m) of
torque.
C. Connect rod tube to HCU. Tighten coupling nut to 450-550 lb in. (50.9-62.1 N·m) of
torque.
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WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE STATOR VANE (VSV)
STAGES 3 TO 5 BUSHING REPLACEMENT
(HIGH-BOSS HPC STATOR CASE)
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC HIGH-BOSS CASE HPC STATOR
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 20
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 19 ...... 5
20 Blank . . . . . . 5
Alphabetical Index
Subject Page
HPC Stages 3 to 5 Bushing Replacement.................................................................................... 5
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1. Introduction.
This work package provides instruction for replacement of high-boss case stages 3 to 5 high pressure
compressor (HPC) variable stator vane (VSV) bushings on engine while engine is installed in the
package.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Maintenance Considerations Chapter II
Variable Stator Vane (VSV) Actuator Component WP 1410 00
Replacement
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Engine Assembly External Tubing, Harnesses, and Clamping SWP 1913 04
High Pressure Compressor (HPC) Stator Vanes Replacement WP 2412 00
Gas Turbine External Inspection (Visual) WP 4012 00
Variable Stator Vane Off-Schedule Inspection WP 4028 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Tool Set, Jackscrew 1C9150G02
Fixture Set, VSV Torque Measuring 1C9408G02
Fixture, Retention, HPC Variable Stator 1C9412P01
Vane
Wrench, VSV Locknut Torque Break 1C9428G01
Wrench, VSV Spacer Spanner 2C6647G01
Handle, Stator Vane Tang Extension Local Manufacture
Pull Scale, 0-50 lb Local Purchase
Pliers, Soft Jaw Local Purchase
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4. Consumable Material.
Nomenclature Specification
Anti-Seize Compound Milk of Magnesia
(Unflavored)
Isopropyl Alcohol Fed Spec TT-I-735
Marking Pen Sharpie T.E.C.
(Black or Blue)
Safety Cable 736L680G01
(R297P04 ALT)
Safety Wire (0.032 inch) Fed Spec SS-S-736
Thread Lubricant GP460
5. Expendable Material.
NOTE
Quantities below are for complete change for all three stages.
Smaller quantities are required if individual bushing changes
are accomplished.
Nomenclature Part No. Qty
Bushing, Vane Actuation (Stg 3 and 4) 1704M66P05 92
Bushing, Vane Actuation (Stg 3 and 4 - 1704M68P09 02
above split-line, left side)
Bushing, Vane Actuation (Stg 3 and 4 - 2nd 1704M68P05 02
above split-line, left side)
Bushing, Vane Actuation (Stg 5) 1704M66P06 56
Bushing, Vane Actuation (Stg 5 - above 1704M68P10 01
split-line, left side)
Bushing, Vane Actuation (Stg 5 - 2nd above 1704M68P06 01
split-line, left side)
Sleeve, Actuation Ring (Stg 3, 4, and 5) 9146M80P03 AR
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6. Recommended Material.
NOTE
• Quantities expressed below are the maximum required for a complete
change. Quantity actually required will vary depending on severity of
bushing wear.
• If self-locking bolts, PN 1855M35P06 or P07, are installed in bushings,
it is recommended to replace them with current bolts, 1855M35P08.
Quantity per Quantity
Nomenclature Part Number Engine Recommended
Bolt, Machine, Self-Locking 1855M35P08 305 AR
Bolt, Machine J644P04F 3 AR
Jamnut AN316C4R 154 AR
Nut, Self-Locking J574P02D 154 AR
Sleeve, Compressor Stator 1704M61P03 154 AR
Spacer (Stg 3 and 4) 1704M62P04 96 AR
Spacer (Stg 5) 1704M62P05 58 AR
Arm, Vane Actuation, Stg 3 1704M63G07 42 AR
Arm, Vane Actuation, Stg 3 1704M63G08 4 AR
Arm, Vane Actuation, Stg 4 1704M63G09 46 AR
Arm, Vane Actuation, Stg 4 1704M63G10 4 AR
Arm, Vane Actuation, Stg 5 1704M63G11 50 AR
Arm, Vane Actuation, Stg 5 1704M63G12 8 AR
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7. HPC Stages 3 to 5 Bushing Replacement.
A. Before disassembly, inspect VSV actuation system for problems per applicable section
of WP 4012 00 and IGV to stage 5 stator vanes for off-schedule condition per
WP 4028 00. Obtain vane retention fixture, 1C9412, or locally manufacture vane tang
extension handle per figure 1.
B. Perform the following:
(1) Remove any interfering tubing or electrical cables per appropriate work packages
(SWP 1913 02 and SWP 1913 04).
(2) Remove VSV actuation lever arms per WP 1410 00.
(3) Remove VSV connecting links as follows:
(a) Using marking pen, mark stage number on connecting links to be removed.
(b) Remove bolts, washers, and lineup pin from stages 3 and 4 connecting links
and remove links from actuation rings. Retain sleeves, if not damaged, for
reinstallation.
(c) Remove bolts from stage 5 connecting links and remove links from actuation
rings. Retain sleeves, if not damaged, for reinstallation.
1
Figure 1. Locally Manufactured Vane Tang Extension Handle
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C. Remove any safety cable or safety wire from all bushings to be replaced. Ensure that all
safety-cable/safety-wire pieces are removed from VSV area to prevent binding in rotat-
ing elements and to prevent any cable or wire from entering the HPC flowpath (FOD
risk).
D. Starting at left horizontal splitline (ALF) and working clockwise, number all bushings
or housing using marking pen.
NOTE
In the event that bushings are replaced randomly, i.e., not a com-
plete stage is replaced, new bushings should be marked, using the
shallow vibropeen method, on the aft facing edge with the number
of engine hours at time of replacement. This will aid in identifying
replaced bushings and determining length of bushing service.
E. Starting at bushing or housing marked number 1, remove bushings or housing as fol-
lows (figure 2 or figure 2.A):
NOTE
It is recommended that the vane assemblies be disassembled and
reassembled one at a time to ensure that reusable parts are not
mixed. If more than one vane assembly is to be disassembled at a
time, care must be taken to ensure that reusable parts are placed
on the same vane assembly from which they were removed.
(1) Note direction of V scribed in end of vane tang. Ensure apex of each V is pointing
forward.
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Figure 2. High-Boss Stages 3 to 5 Configuration Before Service Bulletin LM6000-IND-0213
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Figure 2.A High-Boss Stages 3 to 5 Configuration After Service Bulletin LM6000-IND-0213
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CAUTION
• Extreme caution must be used when disassembling vane bushings.
Once the bushing is removed, the vane may be easily dropped or
rotated in the case. This may cause damage to the vane which
would necessitate replacement. Care must be taken to maintain
control of the vane at all times while the bushing and attaching
hardware are removed, to avoid vane damage and need to remove
HPCS top case.
• Movement of the HPC rotor even in small increments during
bushing removal may cause irreparable damage to the vane and
scoring of the rotor surface. Extreme caution shall be taken to
ensure that the rotor does not turn during this procedure.
(2) Loosen locknut (1) with torque break wrench, 1C9428, and channel lock pliers
(figure 3). If torque break wrench, 1C9428, is not available, use standard socket
or wrench to loosen nut. Provide countertorque on lever arm body using soft jaw
pliers. Remove locknut and lever arm (2, figure 2 or figure 2.A). Inspect lever arm
for serviceability per WP 4012 00, table 8. Remove actuation ring sleeve (10)
from actuation ring (11).
CAUTION
When using a screwdriver to hold vane in position, do not
apply excessive force on vane or damage to vane will occur. A
nonmetallic contact surface is recommended.
NOTE
When removing bushings from upper case or lower case near
split-line, use step (3). When removing bushings from the lower
case, use step (4).
(3) Remove jamnut (3), alignment sleeve (4), and spacer (5) from upper case as
follows:
(a) Hold vane (9) with spacer spanner wrench, 2C6647. Break torque on jamnut
(3). Remove wrench.
(b) Ensuring vane (9) does not turn, install vane retention fixture, 1C9412, or
locally manufactured tool onto end of vane stem.
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Figure 3. Locknut Removal Tool (High-Boss)
(c) Insert small blade-tipped screwdriver under spacer (5). Gently lift spacer and
alignment sleeve (4) while slowly sliding screwdriver in until it contacts vane
stem. Apply gentle force against the vane stem to hold vane (9) in case.
Remove vane retention fixture or locally manufactured tool.
(d) While still maintaining force on vane stem with screwdriver, remove jamnut
(3), alignment sleeve (4), and spacer (5).
(e) Reinstall vane retention fixture on vane stem and remove screwdriver.
(4) Remove jamnut (3), alignment sleeve (4), and spacer (5) from lower case as
follows:
(a) Hold vane (9) with spacer spanner wrench, 2C6647. Break torque on jamnut .
Remove wrench.
(b) Remove jamnut (3), alignment sleeve (4), and spacer (5).
(c) Ensuring vane (9) does not turn, install vane retention fixture, 1C9412, or
locally manufactured fixture onto end of vane stem.
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(5) Before Service Bulletin LM6000-IND-0213, remove bushing (6) as follows:
(a) Examine bushings (6) and securing bolts (7) to ensure that bolts are clamping
bushing in place. If bushings are loose, threaded holes in case must be
examined to determine if repair is needed.
(b) Remove bolts (7) securing bushings (6) to case.
(c) Remove bushings (6) from case. Bushings next to the borescope ports do not
have jackscrew holes: use a nylon drift and small screwdriver to loosen, as
required.
(d) If installed, remove and discard preformed packing (8). Packing will not be
reinstalled at assembly.
NOTE
Service Bulletin LM6000-IND-0213 introduced multiple-piece bushings
in which the components may be replaced individually. Serviceable
housings may be reused while flanged bushings and washers are
replaced.
(6) After Service Bulletin LM6000-IND-0213, remove washer (8), housing (6), and
bushing (13) as follows (figure 2.A):
(a) Examine housing (6) and securing bolts (7) to ensure that bolts are
clamping housing in place. If housings are loose, threaded holes in case must
be examined to determine if repair is needed.
(b) Remove bolts (7) securing housing (6) to case.
(c) Remove washer (8), housing (6), and bushing (13) from case. Retain
serviceable housing for reuse.
F. Clean HPC case in area of bushings, taking care to ensure that no material enters the
HPC case. Remove all preformed packing residue and inspect HPC case for damage
per WP 4012 00.
G. Inspect threaded holes in high-boss case (12). Ensure internal threads are not
damaged.
H. Inspect vane tang and threaded stem for damage.
I. Install bushings (6) or housing (6) in case as follows (figure 2 or figure 2.A):
(1) Before Service Bulletin LM6000-IND-0213, install bushing (6) into high-boss
case (12).
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NOTE
Service Bulletin LM6000-IND-0213 introduced multiple-piece
bushings in which the components may be replaced individually.
Serviceable housings may be reused while flanged bushings and
washers are replaced.
(1.A)After Service Bulletin LM6000-IND-0213, pre-assemble multiple-piece bushing
assemblies as follows:
CAUTION
• Part Numbers are not marked on new bushings and are difficult
to differentiate by size and shape. Stage 5 bushings have a paint
marking on bushing barrel and stage 3 and 4 bushings have no
paint markings. Failure to assemble correctly may cause VSV
off-schedule operation.
• Part Numbers are not marked on new washers and are difficult
to differentiate by size and shape. Stage 5 washers have a paint
marking on washer face and stages 3 and 4 washers have no
paint markings. Failure to assemble correctly may cause VSV
off-schedule operation.
(a) Inspect housings (6) for wear or galling. Reuse only if there is no evidence of
wear or galling.
(b) Pre-assemble multiple-piece bushing assemblies for stages 3, and 4 as follows:
1 Insert barrel end of unpainted stages 3, and 4 flanged bushing (13), inside
barrel end of stages 3 and 4 compressor stator vane actuation housing (6).
2 Insert unpainted stages 3 and 4 flat washer (8), in recessed area on housings
assembled in previous step.
(c) Pre-assemble multiple-piece bushing assemblies for stage 5 as follows:
1 Insert barrel end of painted stage 5 flanged bushing (13), inside barrel end of
stage 5 compressor stator vane actuation housing (6).
2 Insert painted stage 5 flat washer (8), in recessed area on housings
assembled in previous step.
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(1.B)After Service Bulletin LM6000-IND-0213, install multiple-piece bushing assemblies
into HPCS cases as follows:
CAUTION
Multiple-piece bushing assemblies with cutouts are installed at
borescope locations. Improper installation will prevent borescope
use
NOTE
Once assembled, the new multiple-piece bushing assemblies are
installed in the same manner as the one-piece bushing
(a) Install multiple-piece bushing assemblies, pre-assembled in step 1.A.(a) HPCS
stages 3, and 4 high-boss case outer bores.
(b) Install multiple-piece bushing assemblies with cutouts, pre-assembled in step
1.A.(a) into HPCS stages 3, and 4 high-boss case outer bores adjacent to
borescope ports.
(c) Verify that borescope ports in stages 3, and 4 are not blocked. If blocked, repeat
steps 1, and 2. If not blocked, perform remaining installation steps.
(d) Install multiple-piece bushing assemblies, pre-assembled in step 1.A.(b) into
HPCS stage 5 high-boss case outer bores
CAUTION
The bolts, J644, are non-self-locking bolts and must be safety-
wired or bolts may vibrate loose.
NOTE
There are 3 bolts, J644P04F, indicated in the parts list (paragraph 6).
These bolts are to be used, one per stage, in one of the bushings adjacent
to the borescope plug. This bolt is configured with a safety-wire hole
and is to be used to safety-wire the borescope plug in position.
(2) Visually check for evidence of locking feature on bolts (7). Lightly coat threads and
seating surfaces of bolts with thread lubricant.
(a) Install self-locking bolts by hand into case. If bolts can be run into case without
stopping, self-locking feature is not adequate. Replace bolt with new bolt.
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(b) If bolthole condition does not allow any self-locking fastener to engage
locking feature, remove adjacent self-locking bolt and install two
non-self-locking bolts so they may be safety-wired or safety-cabled together.
(3) Secure bushing (6) or housing (6) with two bolts (7), 1855M35P08 or J644P04F.
Install bolts by hand into case. Maximum installation torque of bolts is not to
exceed 40 lb in. (4.5 N·m). Tighten bolts to 85-105 lb in. (9.6-11.9 N·m) of torque.
Install non-self-locking bolts at borescope locations. Safety-wire or safety-cable
bolts to adjacent borescope plug.
CAUTION
When using a screwdriver to hold vane in position, do not
apply excessive force on vane or damage to vane will occur. A
nonmetallic contact surface is recommended.
NOTE
When installing spacer (5), alignment sleeve (4), and jamnut (3)
in upper case or lower case near split line, use step (4). When
installation is in lower case, use step (5).
(4) Install spacer (5), alignment sleeve (4), and jamnut (3) into upper case as follows:
(a) Using small blade tipped screwdriver, apply gentle force against vane stem to
hold vane (9) in position.
(b) Ensuring vane (9) does not turn, remove vane retention fixture.
(c) Install spacer (5) and alignment sleeve (4) onto vane (9). Flat on alignment
sleeve faces forward.
(d) Install jamnut (3) onto vane (9).
(e) Remove screwdriver.
(f) Install spacer spanner wrench, 2C6647, or soft jaw pliers over spacer (5) to
hold vane (9).
(g) Tighten jamnut (3) to 50-70 lb in. (5.6-7.9 N·m) of torque. Replace jamnut if
run-on torque exceeds 20 lb in. (2.3 N·m).
(h) Remove wrench or pliers.
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(5) Install spacer (5), alignment sleeve (4), and jamnut (3) into lower case as follows:
(a) Ensuring vane does not turn, remove vane retention fixture.
(b) Install spacer (5) and alignment sleeve (4) onto vane (9). Flat on alignment
sleeve faces forward.
(c) Install jamnut (3) onto vane (9).
(d) Install spacer spanner wrench, 2C6647, over spacer to hold vane.
(e) Tighten jamnut (3) to 50-70 lb in. (5.6-7.9 N·m) of torque. Replace jamnut if
run-on torque exceeds 20 lb in. (2.3 N·m).
(f) Remove wrench.
CAUTION
Ensure that all stages 3-5 stator vanes have the letter V marked
at top of vane stem. Apex of V shall point forward. Failure to
comply may result in serious engine or part damage.
NOTE
A 0.0 lb in. (0.0 N·m) torque limit implies that vane can rotate
with a minimum force applied. However, it is important to
ensure that the vane assembly is not loose after assembly as a
result of a spacer that is too thin. Vane assembly should be tight
and should not rattle or demonstrate any looseness.
(6) Reset torque wrench to 10 lb in. (1.1 N·m). Manually rotate vane (9) several times
to ensure vane is seated. Ensure vane rotational torque is within range of 0 to 10
lb in. (0.0 to 1.1 N·m). Replace spacer (5) as required to obtain proper rotational
torque. A thinner spacer will reduce rotational torque. A thicker spacer will
increase rotational torque. Record rotational torque.
(7) Small changes to vane rotational torque may be accomplished by lapping spacer
(5) face, using a figure eight motion to remove material. Final surface finish shall
match original.
(8) Install new actuation ring sleeve (10) into actuation ring (11).
(9) Install lever arm (2) onto vane (9). Flat on lever arm faces forward. Insert pin end
of lever arm into actuation ring sleeve.
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(10) Install locknut (1) onto vane (9) by hand. If nuts can be run onto vane without
stopping, self-locking feature is not adequate. Replace nut with new nut. Tighten
locknut to 50-70 lb in. (5.6-7.9 N·m) of torque. Take care when torquing nut to
prevent lever arm damage.
J. Once all bushings in a stage have been replaced, perform actuation ring pull check as
follows:
NOTE
There are two methods for performing the actuation ring pull
check. The first uses the torque measuring fixture set, 1C9408,
and the other uses a pull scale. Perform only the paragraphs
that correspond with the method used.
(1) Using torque measuring fixture set, 1C9408, perform pull check on stages 3-5 as
follows:
(a) Remove parts from vane near center of actuation ring per figure 4.
(b) Remove sleeve from actuation ring.
(c) Install dummy lever arm, locator plug, and drive adapter from fixture set,
1C9408.
(d) Tighten locator plug to 50-70 lb in. (5.6-7.9 N·m) of torque.
(e) Measure torque required to move actuation ring +5 degrees from axial
position per figure 5. On stages 3 and 4, torque required shall not exceed
140 lb in. (15.8 N·m). On stage 5, torque required shall not exceed 204 lb in.
(23.0 N·m).
(2) Perform pull check using a pull scale as follows:
(a) Install slave bolt into actuation ring connecting link bolthole.
(b) Attach pull scale to slave bolt.
(c) Measure force required to move actuation ring +5 degrees from axial position
per figure 5. Multiply reading by the following scale factors to obtain torque:
Stage Scale Factor
3 2.18 inches (55.4 mm)
4 1.92 inches (48.8 mm)
5 1.20 inches (30.5 mm) (Before Service Bulletin LM6000-IND-0203)
1.46 inches (37.1 mm) (After Service Bulletin LM6000-IND-0203)
16 Change 5
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WP 1412 00
Figure 4. VSV Actuation Ring Pull Check
Change 5 17
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WP 1412 00
Figure 5 VSV Actuation Ring Travel
(d) On stages 3 and 4, torque required shall not exceed 140 lb in. (15.8 N·m). On
stage 5, torque required shall not exceed 204 lb in. (23.0 N·m).
(3) Actuate each stage by hand, through complete open and closed mechanical travel.
Each stage shall move freely with no catching or binding.
(4) If pull check requirements are not met, perform the following:
(a) Check actuation ring spacer clearance per figure 6. Adjust as required.
(b) Check for vane binding at casing bore. Correct as required.
(c) Check recorded rotational torques for individual vanes per step I.(6). Replace
or rework spacers on vanes with high torques per step I.(6) and (7).
(d) Repeat steps as necessary to bring torque values into range required. If the
requirements cannot be met, contact GE Engineering Support for further
direction.
K. Reassemble VSV actuating ring connecting links as follows:
(1) Install sleeves into connecting link ID. Ensure connecting link is correct for stage
being installed.
18 Change 5
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Figure 6. Actuation Ring Spacer Clearance
(2) Position connecting link onto actuation rings, ensuring FWD marking faces
forward. Install stage 3 and 4 lineup pins, ensuring lever arm pins engage sleeves.
(3) Install bolts. Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety-wire
or safety-cable.
(4) Ensure that all lever arm pins are engaged in sleeves and not engaged with
connecting link lightening holes.
L. Reinstall actuation levers per WP 1410 00.
M. Reconnect all piping and electrical connections per appropriate work packages.
Change 5 19/(20 Blank)
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WP 1510 00
4WP 1510 00
WORK PACKAGE
TECHNICAL PROCEDURES
GAS/STEAM FUEL SYSTEM COMPONENTS
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 16
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 16 ...... 0
Alphabetical Index
Subject Page
Fuel Nozzle Installation .............................................................................................................. 3
Fuel Nozzle Removal.................................................................................................................. 3
Natural Gas or Steam Manifold Lower Section Installation....................................................... 15
Natural Gas or Steam Manifold Lower Section Removal .......................................................... 13
Natural Gas or Steam Manifold Upper Section Installation ....................................................... 11
Natural Gas or Steam Manifold Upper Section Removal........................................................... 7
Natural Gas or Steam Supply Hose Installation.......................................................................... 6
Natural Gas or Steam Supply Hose Removal ............................................................................. 6
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1510 00
1. Introduction.
This work package contains instructions for replacement of the fuel nozzles, supply hoses, steam
manifold, and natural gas manifold. (Reference kit, PN 682L179.)
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Steam/Fuel Manifold Shipping Bracket Fixture Replacement WP 3015 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture Assy, Shipping Bracket - 1C9381G01
Steam/Fuel Manifold
Fixture, Fuel Nozzle Mounting/Drilling 2C6883G01
Sling, General Purpose Local Purchase
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GP460
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal L45921P01 2
Seal 9371M19P08 1
Seal Ring 9016M30P02 30 (1 per
installed
fuel nozzle)
Seal Ring 9559M20G01/G02 (ALT)
Seal, Inlet Flange Packager-Supplied 1
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6. Fuel Nozzle Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply
may result in part damage.
NOTE
Various brackets may require removal with fuel nozzles. Ensure
brackets are tagged for location and orientation prior to removal.
A. Disconnect natural gas and steam supply hose from fuel nozzle (figure 1).
B. Remove bolts that secure fuel nozzle onto compressor rear frame (CRF). Remove fuel
nozzle and seal ring. Discard seal ring.
1
C. If fuel nozzle bolt breaks during removal, use drilling fixture, 2C6883 (figure 2), to
remove broken bolt as follows:
(1) Position three lockscrews in unlocked position.
2
(2) Align drill bushing hole over broken bolt and align other two holes with tapped holes
in pad.
(3) Install two bolts through body and into tapped holes. Tighten bolts finger-tight.
(4) Turn three lockscrews and lock body to fuel nozzle hole.
(5) Select drill bushing size required and install in body.
(6) Drill broken bolt.
(7) Remove fixture.
(8) Remove broken bolt.
7. Fuel Nozzle Installation.
A. Install new seal ring onto fuel nozzle (figure 1).
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Figure 1. Fuel Nozzles and Supply Hoses
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Figure 2. Fuel Nozzle Mounting/Drilling Fixture
CAUTION
Use care when installing fuel nozzles. Do not force fuel nozzles into
position. Failure to comply may result in fuel nozzle tip or swirl cup
damage.
B. Install fuel nozzle through CRF. Align seal ring with fuel nozzle boltholes.
C. Lubricate bolts with thread lubricant and install through fuel nozzle, seal ring, and
brackets, as required.
D. Tighten each fuel nozzle bolt to 50 lb in. (5.6 N·m) of torque, then tighten to
80-90 lb in. (9.0-10.2 N·m) of torque.
E. After 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in. (9.0-10.2 N·m) of
torque.
F. After an additional 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in.
(9.0-10.2 N·m) of torque and safety-wire bolts in groups of three.
G. Apply thread lubricant onto fuel nozzle inboard and outboard fitting threads.
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WP 1510 00
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
H. Connect steam supply hose onto fuel nozzle inboard fitting. Tighten coupling nut to
75-91 lb ft (102-123 N·m) of torque.
I. Connect natural gas supply hose onto fuel nozzle outboard fitting. Tighten coupling
nut as follows:
(1) Tighten coupling nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
8. Natural Gas or Steam Supply Hose Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect natural gas or steam supply hose from manifold (figure 1).
B. Disconnect natural gas or steam supply hose from fuel nozzle. Remove hose.
9. Natural Gas or Steam Supply Hose Installation.
A. Apply thread lubricant onto manifold fitting and fuel nozzle fittings threads (figure 1).
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
B. Connect natural gas hose onto natural gas manifold and onto fuel nozzle outboard
fitting. Tighten coupling nuts as follows:
(1) Tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque.
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(2) Loosen until coupling nuts are free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nuts by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
C. Connect steam supply hose onto steam supply manifold and onto fuel nozzle inboard
fitting. Tighten coupling nuts to 75-91 lb ft (102-123 N·m) of torque.
10. Natural Gas or Steam Manifold Upper Section Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect natural gas or steam supply hoses from manifold upper section
(figure 3 or 4).
4
3
NOTE
If fuel or steam manifold inlet flange is located at 6:00 o'clock
position, disregard step B. If fuel and steam manifold inlet
flange is located at 12:00 o'clock position, disregard step C.
B. Remove bolts and nuts that secure manifold inlet flange.
C. If installed, disconnect vent line at 12:00 o'clock position. If manifold will be
replaced, remove fitting or plug and seal. Discard seal.
WARNING
Manifold section with inlet flange weighs 104 pounds
(47 kg). Manifold section without inlet flange weighs
81 pounds (37 kg). Ensure adequate personnel are available
for manual removal of manifolds. Failure to comply may
result in engine damage or serious injury.
D. Install sling and 250-pound (113 kg) capacity hoist on manifold upper section, if
enclosure configuration permits. If sling and hoist cannot be installed, manifold
section must be removed manually.
E. Remove nuts, washers, and bolts from manifold section mounting flanges (figure 5).
5
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WP 1510 00
Figure 3. Natural Gas Manifold
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Figure 4. Steam Manifold
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Figure 5. Natural Gas and Steam Manifolds
10
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NOTE
Removing or changing position of packager-supplied stanchion will
require use of steam/fuel manifold shipping bracket fixture assem-
bly, 1C9381, to relocate fuel or steam manifold to proper position.
F. Disconnect packager-supplied mount braces from manifold upper brackets.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
G. Remove manifold upper section. Discard seal gaskets (figure 5).
11. Natural Gas or Steam Manifold Upper Section Installation.
WARNING
• Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds
(37 kg). Ensure adequate personnel are available for manual
removal of manifolds. Failure to comply may result in engine
damage or serious injury.
• Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or
fall, they can cause an injury or kill you.
CAUTION
• Do not deform hoses if lowering manifold lower section to
gain clearance for installation of manifold upper section.
Failure to comply may result in hose or fuel nozzle damage.
• If packager-supplied stanchions were moved, fuel or steam
manifold must be positioned with fuel/steam manifold support
bracket fixture assembly, 1C9381, per WP 3015 00. Failure to
comply may result in hose or fuel nozzle damage.
A. Install sling and 250-pound (113 kg) capacity hoist onto manifold upper section, if
enclosure configuration permits. If sling and hoist cannot be installed, manifold
section must be installed manually. Install manifold upper section.
11
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WP 1510 00
B. Install three adjacent bolts through manifold section flanges. Install nuts and washers,
washers under nuts. Leave sufficient gap between flanges to insert gasket.
C. Install seal gaskets between manifold section flanges (figure 5). Install five remaining
bolts through manifold section flanges. Install nuts and washers, washers under nuts.
D. Tighten manifold section flange nuts to 220-250 lb in. (24.9-28.2 N·m) of torque.
E. Connect packager-supplied mount braces onto manifold upper section brackets with
packager-supplied fasteners.
F. Tighten fasteners that secure packager-supplied mount braces onto manifold upper
section brackets to 480-570 lb in. (54.2-64.4 N·m) of torque.
NOTE
If fuel and steam manifold inlet flange is located at 12:00
o'clock position, disregard steps G., H., and I.
G. Install three adjacent bolts through inlet flanges. Install nuts, but leave sufficient gap
between flanges to insert gasket.
H. Install packager-supplied seal gasket between inlet flanges. Install five remaining bolts
through inlet flanges. Secure with nuts.
I. Tighten 12:00 o'clock position inlet flange bolts and nuts to 235-265 lb ft
(319-359 N·m) of torque.
NOTE
If fuel and steam manifold inlet flange is located at 12:00
o'clock position, disregard steps J., K., and L.
J. Install seal onto manifold vent fitting or plug (figure 3 or 4).
K. Install manifold vent fitting or plug into manifold. Tighten to 450-550 lb in.
(50.8-62.1 N·m) of torque.
L. Install packager-supplied vent line onto manifold vent fitting, if required. Tighten
coupling nut to 450-550 lb in. (50.8-62.1 N·m) of torque.
M. Apply thread lubricant onto vent fitting threads.
N. Install packager-supplied vent line onto manifold vent fitting, if required. Tighten
coupling nut to 450-550 lb in. (50.8-62.1 N·m) of torque.
12
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O. Apply thread lubricant onto natural gas and steam supply hose coupling nut threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
P. Connect steam supply hose onto appropriate manifold. Tighten coupling nuts to
75-91 lb ft (102-123 N·m) of torque.
Q. Connect natural gas supply hose onto appropriate manifold. Tighten coupling nuts as
follows:
(1) Assemble and tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque at
each joint sequentially around in a clockwise direction aft looking forward (ALF).
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque at each joint sequentially around in a clockwise direction
ALF.
(3) Check joint by reapplying 78-92 lb ft (106-125 N·m) of torque to the coupling nut
in the tightening direction at each joint sequentially around in a clockwise
direction ALF.
12. Natural Gas or Steam Manifold Lower Section Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect natural gas or steam supply hoses from manifold lower section
(figure 3 or 4).
NOTE
If fuel and steam manifold inlet flange is located at 12:00 o'clock
position, disregard step B. If fuel and steam manifold inlet flange is
located at 6:00 o'clock position, disregard step C.
B. Remove bolts and nuts that secure manifold inlet flange.
C. If installed, disconnect vent line at 6:00 o'clock position. If manifold will be replaced,
remove fitting or plug and seal. Discard seal.
13
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WP 1510 00
CAUTION
Removing or changing position of packager-supplied stanchion
will require use of steam/fuel manifold shipping bracket fixture
assembly, 1C9381, to relocate fuel or steam manifold to proper
position.
D. Disconnect packager-supplied mount braces from manifold lower section brackets.
E. Remove nuts, washers, and bolts from manifold section mounting flanges (figure 5)
WARNING
• Manifold section with inlet flange weighs 104 pounds
(47 kg). Manifold section without inlet flange weighs
81 pounds (37 kg). Ensure adequate personnel are avail-
able for manual removal of manifolds. Failure to comply
may result in engine damage or serious injury.
• Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts acciden-
tally move or fall, they can cause an injury or kill you.
CAUTION
Do not deform hoses if raising manifold upper section to gain
clearance for removal of manifold lower section. Failure to
comply may result in hose or fuel nozzle damage.
F. Remove manifold lower section. Discard seal gaskets (figure 5).
14
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WP 1510 00
13. Natural Gas or Steam Manifold Lower Section Installation.
WARNING
Manifold section with inlet flange weighs 104 pounds
(47 kg). Manifold section without inlet flange weighs
81 pounds (37 kg). Ensure adequate personnel are available
for manual removal of manifolds. Failure to comply may
result in engine damage or serious injury.
CAUTION
• Do not deform hoses if raising manifold upper section to
gain clearance for installation of manifold lower section.
Failure to comply may result in hose or fuel nozzle damage.
• If packager-supplied stanchions were moved, fuel or steam
manifold must be positioned with fuel/steam manifold support
bracket fixture assembly, 1C9381, per WP 3015 00.
A. Manually install manifold lower section.
B. Install three adjacent bolts through manifold section flanges (figure 5). Install nuts and
washers, washers under nuts. Leave sufficient gap between flanges to insert gasket.
C. Install seal gaskets between manifold section flanges (figure 5). Install five remaining
bolts through manifold section flanges. Install nuts and washers, washers under nuts.
D. Tighten manifold section flange nuts to 220-250 lb in. (24.9-28.2 N·m) of torque.
E. Connect packager-supplied mount braces onto manifold lower section brackets with
packager-supplied fasteners.
F. Tighten fasteners that secure packager-supplied mount braces onto manifold lower
section brackets to 480-570 lb in. (54.2-64.4 N·m) of torque.
NOTE
If fuel or steam manifold inlet flange is located at 12:00 o'clock
position, disregard steps G., H., and I.
G. Install three adjacent bolts through inlet flanges. Install nuts, but leave sufficient gap
between flanges to insert gasket.
15
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H. Install packager-supplied seal gasket between inlet flanges. Install five remaining bolts
through inlet flanges. Secure with nuts.
I. Tighten 6:00 o'clock position inlet flange nuts to 235-265 lb ft (319-359 N·m) of
torque, if required.
NOTE
If fuel or steam manifold inlet flange is located at 6:00 o'clock
position, disregard steps J., K., and L.
J. Install seal onto manifold vent fitting or plug (figure 3 or 4).
K. Apply thread lubricant onto vent fitting or plug threads.
L. Install manifold vent fitting or plug into manifold. Tighten to 450-550 lb in.
(50.8-62.1 N·m) of torque.
M. Apply thread lubricant onto vent fitting threads.
N. Install packager-supplied vent line onto manifold vent fitting, if required. Tighten
coupling nut to 450-550 lb in. (50.8-62.1 N·m) of torque.
O. Apply thread lubricant onto natural gas or steam supply hose coupling nut threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
P. Connect steam supply hose onto appropriate manifold. Tighten coupling nuts to
75-91 lb ft (102-123 N·m) of torque.
Q. Connect natural gas supply hose onto appropriate manifold. Tighten coupling nuts as
follows:
(1) Assemble and tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque at each
joint sequentially around in a clockwise direction ALF.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque at each joint sequentially around in a clockwise direction
ALF.
(3) Check joint by reapplying 78-92 lb ft (106-125 N·m) of torque to the coupling nut
in the tightening direction at each joint sequentially around in a clockwise
direction ALF.
16
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WP 1511 00
4WP 1511 00
WORK PACKAGE
TECHNICAL PROCEDURES
DUAL FUEL/WATER FUEL SYSTEM COMPONENTS
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 28
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 27 ...... 0
28 Blank . . . . . . 0
Alphabetical Index
Subject Page
Fuel Feeder Tube Installation...................................................................................................... 9
Fuel Feeder Tube Removal ......................................................................................................... 9
Fuel Manifold Block Assembly .................................................................................................. 24
Fuel Manifold Block Disassembly.............................................................................................. 23
Fuel Manifold Block Installation ................................................................................................ 24
Fuel Manifold Block Removal.................................................................................................... 21
Fuel Nozzle Installation .............................................................................................................. 6
Fuel Nozzle Removal.................................................................................................................. 4
Fuel Supply Hose Installation ..................................................................................................... 11
Fuel Supply Hose Removal......................................................................................................... 10
Natural Gas Manifold Lower Section Installation ...................................................................... 17
Natural Gas Manifold Lower Section Removal.......................................................................... 16
Natural Gas Manifold Upper Section Installation....................................................................... 14
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WP 1511 00
Alphabetical Index - Continued
Subject Page
Natural Gas Manifold Upper Section Removal........................................................................... 11
Natural Gas Supply Hose Installation ......................................................................................... 9
Natural Gas Supply Hose Removal ............................................................................................. 8
Primary or Secondary Fuel Supply Manifold Installation........................................................... 19
Primary or Secondary Fuel Supply Manifold Removal .............................................................. 19
1. Introduction.
This work package contains instructions for replacement of fuel nozzles, supply hoses, liquid
fuel manifolds, natural gas manifold, fuel manifold block, and associated components.
(Reference kit, PN 682L178.)
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Steam/Fuel Manifold Shipping Bracket Fixture Replacement WP 3015 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture Assembly, Shipping Bracket - 1C9381G01
Steam/Fuel Manifold
Fixture, Fuel Nozzle Mounting/Drilling 2C6883G01
Pliers, Teflon-Jawed Local Purchase
Sling, General Purpose Local Purchase
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GP460
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5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal L45921P01 2
Seal Ring 9016M30P02 AR
Seal 9371M19P04 2
Seal 9371M19P06 2
Seal 9371M19P08 1
Seal 9371M19P10 3
Seal 9371M19P12 3
Seal, Inlet Flange Packager-Supplied 1
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6. Fuel Nozzle Removal.
A. If required, remove brackets with fuel nozzles per SWP 1913 02. Tag brackets for
location and orientation prior to removal.
WARNING
• Fuel in liquid, vapor, or mist form is flammable, irritating to the
skin and respiratory tract, and poisonous in the digestive tract.
Remove saturated clothing, wash skin well, don't swallow liquid,
and don't breathe mist or vapor.
• Fuel system is pressurized. Use care to prevent injury
when disconnecting lines.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
B. Disconnect natural gas supply hose from fuel nozzle. See figure 1.
C. Loosen primary and secondary fuel feeder tube coupling nuts from primary and
secondary fuel supply manifolds.
CAUTION
Ensure fuel nozzle fittings are restrained when loosening coupling
nut. Failure to comply may result in part damage.
D. Disconnect primary and secondary fuel feeder tubes from fuel nozzle.
E. Remove bolts that secure fuel nozzle onto compressor rear frame (CRF). Position fuel
feeder tubes clear of fuel nozzle. Remove fuel nozzle and seal ring. Discard seal ring.
1
F. If fuel nozzle bolt breaks during removal, use drilling fixture (figure 2), 2C6883, to
remove broken bolt as follows:
(1) Position three lockscrews in unlocked position.
2
(2) Align drill bushing hole over broken bolt and align other two holes with tapped
holes in pad.
(3) Install two bolts through body and into tapped holes. Tighten bolts finger-tight.
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Figure 1. Fuel Nozzles, Feeder Tubes, and Hoses
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Figure 2. Fuel Nozzle Mounting/Drilling Fixture
(4) Turn three lockscrews and lock body to fuel nozzle hole.
(5) Select drill bushing size required and install in body.
(6) Drill broken bolt.
(7) Remove fixture.
(8) Remove broken bolt.
7. Fuel Nozzle Installation.
CAUTION
Fuel nozzles, PN L31476P49 (blue band), is installed at positions 4
and 27 (aft looking forward). For remaining positions, use fuel
nozzle, PN L31496P48 (silver band). Do not mix fuel nozzles.
Failure to comply may result in engine damage.
A. Install new seal ring onto fuel nozzle. See figure 1.
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CAUTION
Use care when installing fuel nozzles. Do not force fuel nozzles
into position. Failure to comply may result in fuel nozzle tip or
swirl cup damage.
B. Install fuel nozzle through CRF. Align seal ring with fuel nozzle boltholes.
C. Lubricate bolts with thread lubricant and install through fuel nozzle, seal ring, and
brackets, as required.
D. Tighten each fuel nozzle bolt to 50 lb in. (5.6 N·m) of torque, then tighten to
80-90 lb in. (9.0-10.2 N·m) of torque.
E. After 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in. (9.0-10.2 N·m) of
torque.
F. After an additional 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in.
(9.0-10.2 N·m) of torque and safety-wire bolts in groups of three.
CAUTION
Ensure fuel nozzle fittings are restrained when tightening
coupling nut. Failure to comply may result in part damage.
G. Connect primary fuel feeder tube onto fuel nozzle inboard fitting and onto primary fuel
supply manifold.
H. Tighten coupling nuts as follows:
(1) Tighten coupling nuts to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(3) Check nuts by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
I. Connect secondary fuel feeder tube onto fuel nozzle center fitting and onto secondary
fuel supply manifold.
J. Tighten coupling nut at fuel nozzle as follows:
(1) Tighten coupling nut to 180-200 lb in. (20.3-22.6 N·m) of torque.
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(2) Loosen until coupling nut is free running and retighten to 180-200 lb in.
(20.3-22.6 N·m) of torque.
(3) Check nut by reapplying 180-200 lb in. (20.3-22.6 N·m) of torque in the
tightening direction.
K. Tighten coupling nut at secondary fuel supply manifold as follows:
(1) Tighten coupling nut to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(3) Check nut by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
L. Apply thread lubricant onto fuel nozzle natural gas fitting threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
M. Connect natural gas supply hose onto fuel nozzle outboard fitting. Tighten coupling
nut as follows:
(1) Tighten coupling nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
8. Natural Gas Supply Hose Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect natural gas supply hose from natural gas manifold. See figure 1.
B. Disconnect natural gas supply hose from fuel nozzle. Remove hose.
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9. Natural Gas Supply Hose Installation.
A. Apply thread lubricant onto natural gas hose coupling nut threads.
B. Connect natural gas supply hose onto natural gas manifold and onto fuel nozzle
outboard fitting.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
C. Tighten coupling nuts as follows:
(1) Tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nuts by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
10. Fuel Feeder Tube Removal.
A. Disconnect primary or secondary fuel feeder tube from fuel supply manifold.
See figure 1.
CAUTION
Ensure fuel nozzle fittings are restrained when loosening coupling
nut. Failure to comply may result in part damage.
B. Disconnect primary or secondary fuel feeder tube from fuel nozzle. Remove fuel
feeder tube.
11. Fuel Feeder Tube Installation.
CAUTION
Ensure fuel nozzle fittings are restrained when tightening
coupling nut. Failure to comply may result in part damage.
A. Connect primary fuel feeder tube onto fuel nozzle inboard fitting and onto primary
fuel supply manifold.
B. Tighten coupling nuts as follows:
(1) Tighten coupling nuts to 135-150 lb in. (15.3-16.9 N·m) of torque.
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(2) Loosen until coupling nuts are free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(3) Check nuts by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
C. Connect secondary fuel feeder tube onto fuel nozzle center fitting and onto secondary
fuel supply manifold.
D. Tighten coupling nut at fuel nozzle as follows:
(1) Tighten coupling nut to 180-200 lb in. (20.3-22.6 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 180-200 lb in.
(20.3-22.6 N·m) of torque.
(3) Check nut by reapplying 180-200 lb in. (20.3-22.6 N·m) of torque in the
tightening direction.
E. Tighten coupling nut at secondary fuel supply manifold as follows:
(1) Tighten coupling nut to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(3) Check nut by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
12. Fuel Supply Hose Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect primary or secondary fuel supply hose from primary or secondary fuel
supply manifold.
B. Disconnect primary or secondary fuel supply hose from fuel manifold block. Remove
hose.
10
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13. Fuel Supply Hose Installation.
A. Apply thread lubricant onto primary and secondary fuel supply hose coupling nut
threads. See figure 1.
B. Connect primary or secondary fuel supply hose onto primary or secondary fuel supply
manifold.
C. Connect primary or secondary fuel supply hose onto appropriate fuel manifold block
fitting.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
D. Tighten primary fuel supply hose coupling nuts as follows:
(1) Tighten coupling nuts to 55-65 lb ft (75-88 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 55-65 lb ft
(75-88 N·m) of torque.
(3) Check nuts by reapplying 55-65 lb ft (75-88 N·m) of torque in the tightening
direction.
E. Tighten secondary fuel supply hose coupling nuts as follows:
(1) Tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nuts by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
14. Natural Gas Manifold Upper Section Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect natural gas supply hoses from manifold upper section. See figure 3.
11
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3
Figure 3. Natural Gas, Primary, and Secondary Fuel Manifolds (Sheet 1 of 2)
12
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Figure 3. Natural Gas, Primary, and Secondary Fuel Manifolds (Sheet 2 of 2)
NOTE
If fuel manifold inlet flange is located at 6:00 o'clock position,
disregard step B. If fuel manifold inlet flange is located at
12:00 o'clock position, disregard step C.
B. Remove bolts and nuts that secure manifold inlet flange.
C. If manifold will be replaced, remove plug and seal. Discard seal.
WARNING
Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds (37 kg).
Ensure adequate personnel are available for manual removal of
manifolds. Failure to comply may result in engine damage or
serious injury.
D. Install sling and 250-pound (113 kg) capacity hoist onto manifold upper section, if
enclosure configuration permits. If sling and hoist cannot be installed, manifold
section must be removed manually.
13
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E. Remove nuts, washers, and bolts that secure upper manifold section flange, detail A.
CAUTION
Removing or changing position of packager supplied stanchion
will require use of steam/fuel manifold shipping bracket fixture
assembly, 1C9381, to relocate natural gas manifold to proper posi-
tion.
F. Disconnect packager-supplied mount braces from manifold brackets, upper section.
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
G. Remove manifold upper section. Discard seal gaskets, detail A.
15. Natural Gas Manifold Upper Section Installation.
WARNING
• Manifold section with inlet flange weighs 104 pounds
(47 kg). Manifold section without inlet flange weighs 81
pounds (37 kg). Ensure adequate personnel are available
for manual installation of manifolds. Failure to comply
may result in engine damage or serious injury.
• Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts acciden-
tally move or fall, they can cause an injury or kill you.
CAUTION
• Do not deform hoses if lowering manifold lower section to
gain clearance for installation of manifold upper section.
Failure to comply may result in hose or fuel nozzle damage.
• If packager-supplied stanchions were moved, natural gas
manifold must be positioned with fuel/steam manifold support
bracket fixture assembly, 1C9381, per WP 3015 00.
A. Install sling and 250-pound (113 kg) capacity hoist onto manifold upper section, if
enclosure configuration permits. If sling and hoist cannot be installed, manifold
section must be installed manually. Install manifold upper section. See figure 3.
14
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B. Install three adjacent bolts through upper manifold section flanges, detail A. Install
nuts and washers, washers under nuts. Leave sufficient gap between flanges to insert
gasket.
C. Install seal gaskets between upper manifold section flanges. Install remaining five
bolts through manifold section flanges. Secure with nuts and washers, washers under
nuts.
D. Tighten manifold section flange nuts to 220-250 lb in. (24.9-28.2 N·m) of torque.
E. Connect packager-supplied mount braces onto manifold brackets, upper section, with
packager-supplied fasteners.
F. Tighten fasteners that secure packager-supplied mount braces onto manifold brackets,
upper section, to 480-570 lb in. (54.2-64.4 N·m) of torque.
NOTE
If fuel manifold inlet flange is located at 6:00 o'clock position,
disregard steps G. and H.
G. Install three adjacent bolts through inlet flanges. Install nuts but leave sufficient gap
between flanges to insert gasket.
H. Install packager-supplied seal gasket between inlet flanges. Install remaining five
bolts through inlet flanges. Secure with nuts.
I. Tighten 12:00 o'clock position inlet flange nuts to 235-265 lb ft (319-359 N·m) of
torque.
NOTE
If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard steps J. and K.
J. Install seal on plug.
K. Apply thread lubricant onto plug threads.
L. Install plug into natural gas manifold. Tighten to 450-550 lb in. (50.8-62.1 N·m) of
torque.
M. Apply thread lubricant onto natural gas manifold fitting threads.
15
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CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
N. Connect natural gas supply hoses onto natural gas manifold. Tighten coupling nuts as
follows:
(1) Assemble and tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque at each
joint sequentially around in a clockwise direction aft looking forward (ALF).
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque at each joint sequentially around in a clockwise direction
ALF.
(3) Check joint by reapplying 78-92 lb ft (106-125 N·m) of torque to the coupling nut
in the tightening direction at each joint sequentially around in a clockwise
direction ALF.
16. Natural Gas Manifold Lower Section Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect natural gas supply hoses from manifold lower section. See figure 3.
NOTE
If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard step B. If fuel manifold inlet flange is located at 6:00
o'clock position, disregard step C.
B. Remove bolts and nuts that secure manifold inlet flange.
C. If manifold will be replaced, remove plug and seal. Discard seal.
CAUTION
Removing or changing position of packager supplied stan-
chion will require use of steam/fuel manifold shipping bracket
fixture assembly, 1C9381, to relocate natural gas manifold to
proper position.
D. Disconnect packager-supplied mount braces from manifold brackets, lower section.
16
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E. Remove nuts, washers, and bolts from lower manifold section flanges.
WARNING
Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds
(37 kg). Ensure adequate personnel are available for manual
removal of manifolds. Failure to comply may result in engine
damage or serious injury.
CAUTION
Do not deform hoses if raising manifold upper section to gain
clearance for removal of manifold lower section. Failure to
comply may result in hose or fuel nozzle damage.
F. Remove manifold lower section. Discard seal gaskets.
17. Natural Gas Manifold Lower Section Installation.
WARNING
Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds
(37 kg). Ensure adequate personnel are available for manual
removal of manifolds. Failure to comply may result in engine
damage or serious injury.
CAUTION
• Do not deform hoses if raising manifold upper section to
gain clearance for installation of manifold lower section.
Failure to comply may result in hose or fuel nozzle damage.
• If packager-supplied stanchions were moved, natural gas
manifold must be positioned with steam/fuel manifold support
bracket fixture assembly, 1C9381, per WP 3015 00.
A. Manually install manifold lower section. See figure 3.
B. Install three adjacent bolts through lower manifold section flanges, detail A. Install nuts
and washers, washers under nuts. Leave sufficient gap between flanges to insert gasket.
C. Install seal gaskets between manifold section flanges. Install remaining five bolts
through lower manifold section flanges, detail A. Secure with nuts and washers,
washers under nuts.
D. Tighten manifold section flange nuts to 220-250 lb in. (24.9-28.2 N·m) of torque.
17
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E. Connect packager-supplied mount braces onto manifold brackets, lower section, with
packager-supplied fasteners.
F. Tighten fasteners that secure packager-supplied mount braces onto manifold brackets,
lower section, to 480-570 lb in. (54.2-64.4 N·m) of torque.
NOTE
If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard steps G., H., and I.
G. Install three adjacent bolts through inlet flanges. Install nuts but leave sufficient gap
between flanges to insert gasket.
H. Install packager-supplied seal gasket between inlet flanges. Install remaining five bolts
through inlet flanges. Secure with nuts.
I. Tighten 6:00 o'clock position inlet flange nuts to 235-265 lb ft (319-359 N·m) of
torque.
NOTE
If fuel manifold inlet flange is located at 6:00 o'clock position,
disregard steps J. and K.
J. Install seal on plug.
K. Apply thread lubricant onto plug threads.
L. Install plug into manifold. Tighten to 450-550 lb in. (50.8-62.1 N·m) of torque.
M. Apply thread lubricant onto natural gas manifold fitting threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
N. Connect natural gas supply hoses onto natural gas manifold. Tighten coupling nuts as
follows:
(1) Assemble and tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque at each
joint sequentially around in a clockwise direction ALF.
18
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(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque at each joint sequentially around in a clockwise
direction ALF.
(3) Check joint by reapplying 78-92 lb ft (106-125 N·m) of torque to the coupling nut
in the tightening direction at each joint sequentially around in a clockwise
direction ALF.
18. Primary or Secondary Fuel Supply Manifold Removal.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect primary or secondary fuel supply hoses from primary or secondary fuel
supply manifold. See figure 3, detail B.
NOTE
Note location of section connectors to aid at installation.
B. Remove nuts, bolts, and washers from primary or secondary fuel supply manifold
section connectors.
C. Remove clamps that secure primary and secondary fuel supply manifolds together.
CAUTION
Ensure fuel nozzle fittings are restrained when loosening cou-
pling nut. Failure to comply may result in part damage.
D. Loosen primary or secondary fuel feeder tube coupling nuts from fuel nozzle.
E. Disconnect fuel feeder tubes from primary or secondary fuel supply manifold.
Remove primary or secondary fuel supply manifold sections.
19. Primary or Secondary Fuel Supply Manifold Installation.
A. Install one primary or secondary fuel supply manifold section onto appropriate
primary or secondary fuel feeder tubes as noted during removal. Orient manifold
section connector as noted at removal. Do not tighten coupling nuts at this time.
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B. Connect remaining primary or secondary fuel supply manifold section onto installed
manifold section. Secure with bolts, nuts, and washers, washers under nuts. Tighten
nuts fingertight.
CAUTION
Ensure fuel manifolds are supported while attaching fuel
feeder tubes.
C. Connect remaining primary and secondary fuel feeder tubes onto primary and
secondary fuel supply manifold. Tighten all fuel feeder tube coupling nuts fingertight.
D. Tighten primary fuel feeder tube coupling nuts at fuel nozzles as follows:
(1) Tighten coupling nuts to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(3) Check nuts by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
E. Tighten secondary fuel feeder tube coupling nuts at fuel nozzles as follows:
(1) Tighten coupling nuts to 180-200 lb in. (20.3-22.6 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 180-200 lb in.
(20.3-22.6 N·m) of torque.
(3) Check nuts by reapplying 180-200 lb in. (20.3-22.6 N·m) of torque in the
tightening direction.
F. Tighten primary and secondary fuel feeder tube coupling nuts at primary or secondary
fuel supply manifold as follows:
(1) Tighten coupling nuts to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(3) Check nuts by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
G. Tighten primary or secondary fuel supply manifold section connecting nuts as follows:
(1) Tighten nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
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(2) Loosen until nuts are free running and retighten to 55-70 lb in. (6.2-7.9 N·m) of
torque.
(3) Check nuts by reapplying 55-70 lb in. (6.2-7.9 N·m) of torque in the tightening
direction.
H. Apply thread lubricant onto primary and secondary fuel supply hose coupling nut
threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
I. Install primary or secondary fuel supply hoses onto primary or secondary fuel supply
manifold. Tighten primary fuel supply hose coupling nut as follows:
(1) Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 55-65 lb ft (75-88 N·m)
of torque.
(3) Check nut by reapplying 55-65 lb ft (75-88 N·m) of torque in the tightening
direction.
J. Tighten secondary fuel supply hose coupling nut as follows:
(1) Tighten coupling nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
K. Install clamps per SWP 1913 02 to hold primary and secondary fuel supply manifolds
together.
20. Fuel Manifold Block Removal.
A. Disconnect primary and secondary fuel supply hoses from primary and secondary fuel
outlet adapters. See figure 4.
4
B. Disconnect primary fuel inlet hoses from primary fuel inlet adapters per packager's
manual.
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Figure 4. Fuel Manifold Block
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C. Disconnect secondary fuel inlet and water supply inlet hoses from secondary fuel inlet
tee fitting, if installed, per packager's manual.
D. Disconnect pressure sensing hoses from primary and secondary fuel supply inlet
pressure sensing adapters.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installa-
tion. Failure to comply may cause unreliable engine operation.
E. Tag and disconnect electrical connectors from primary and secondary fuel
temperature sensors.
F. Remove bolt and clamp that secure secondary fuel inlet tube onto bracket.
G. Remove bolts that secure fuel manifold block onto bracket. Remove fuel manifold
block.
21. Fuel Manifold Block Disassembly.
CAUTION
Ensure fuel manifold block is secured in vise or other suitable
restraining device when removing adapters and temperature
sensors. Failure to comply may result in part damage.
A. Disconnect secondary fuel inlet tube from secondary fuel inlet tube adapter.
See figure 4.
B. Remove secondary fuel inlet adapter. Remove and discard seal.
C. Remove secondary fuel supply inlet pressure sensing adapter. Remove and discard
seal.
D. Remove secondary fuel temperature sensor. Remove and discard seal.
E. Remove primary fuel inlet adapter. Remove and discard seal.
F. Remove primary fuel supply inlet pressure sensing adapter. Remove and discard seal.
G. Remove primary fuel temperature sensor. Remove and discard seal.
23
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H. Remove secondary fuel outlet adapters. Remove and discard seals.
I. Remove primary fuel outlet adapters. Remove and discard seals.
22. Fuel Manifold Block Assembly.
A. Install new seals onto secondary fuel outlet adapters. See figure 4. Install adapters into
secondary fuel outlet ports. Tighten adapters to 540-600 lb in. (61.0-67.8 N·m) of
torque.
B. Install new seals onto primary fuel outlet adapters. Install adapters into primary fuel
outlet ports. Tighten adapters to 360-400 lb in. (40.7-45.2 N·m) of torque.
C. Install new seal onto primary fuel temperature sensor. Install sensor into primary fuel
temperature sensor port. Tighten sensor to 135-150 lb in. (15.3-16.9 N·m) of torque.
D. Install new seal onto primary fuel supply inlet pressure sensing adapter. Install adapter
into primary fuel pressure sensing port. Tighten adapter to 180-200 lb in.
(20.3-22.6 N·m) of torque.
E. Install new seal onto primary fuel inlet adapter. Install adapter into primary fuel inlet
port. Tighten adapter to 360-400 lb in. (40.7-45.2 N·m) of torque.
F. Install new seal onto secondary fuel temperature sensor. Install sensor into secondary
fuel temperature sensor port. Tighten sensor to 135-150 lb in. (15.3-16.9 N·m) of
torque.
G. Install new seal onto secondary fuel supply inlet pressure sensing adapter. Install
adapter into secondary fuel pressure sensing port. Tighten adapter to 180-200 lb in.
(20.3-22.6 N·m) of torque.
H. Install new seal onto secondary fuel inlet tube adapter. Install adapter into secondary
fuel inlet port. Tighten adapter to 540-600 lb in. (61.0-67.8 N·m) of torque.
I. Install secondary fuel inlet tube onto secondary fuel inlet tube adapter. Do not tighten
coupling nut at this time.
23. Fuel Manifold Block Installation.
A. Install fuel manifold block onto bracket with bolts. Tighten bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
B. Secure secondary fuel inlet tube clamp onto fuel manifold block mount bracket with
bolt. Tighten bolt to 55-70 lb in. (6.2-7.9 N·m) of torque.
24
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CAUTION
Ensure fuel manifold block adapters are restrained when
tightening coupling nuts. Failure to comply may result in part
damage.
C. Tighten secondary fuel inlet tube coupling nut as follows:
(1) Tighten coupling nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
D. Connect electrical connectors to primary and secondary fuel temperature sensors as
follows:
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
E. Apply thread lubricant onto primary and secondary fuel supply hose coupling nut
threads.
25
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CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
F. Connect primary fuel supply hoses onto primary fuel outlet adapters. Tighten
coupling nuts as follows:
(1) Tighten coupling nuts to 55-65 lb ft (75-88 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 55-65 lb ft
(75-88 N·m) of torque.
(3) Check nuts by reapplying 55-65 lb ft (75-88 N·m) of torque in the tightening
direction.
G. Connect secondary fuel supply hoses onto secondary fuel outlet adapters. Tighten
coupling nuts as follows:
(1) Tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nuts by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
H. Connect packager-supplied primary and secondary fuel supply inlet pressure sensing
hoses to primary and secondary fuel supply inlet pressure sensing adapters. Tighten
coupling nuts as follows:
(1) Tighten coupling nuts to 270-300 lb in. (30.5-33.9 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 270-300 lb in.
(30.5-33.9 N·m) of torque.
(3) Check nuts by reapplying 270-300 lb in. (30.5-33.9 N·m) of torque in the
tightening direction.
I. If required, connect water supply hose onto secondary fuel inlet tee fitting. Tighten
coupling nut to 75-91 lb ft (102-123 N·m) of torque.
26
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J. Connect primary fuel supply inlet hose onto primary fuel inlet adapter. Tighten
coupling nut as follows:
(1) Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 55-65 lb ft (75-88 N·m)
of torque.
(3) Check nut by reapplying 55-65 lb ft (75-88 N·m) of torque in the tightening
direction.
K. Connect secondary fuel supply inlet hose onto secondary fuel inlet tee fitting. Tighten
coupling nut as follows:
(1) Tighten coupling nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
27/(28 Blank)
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4WP 1512 00
WORK PACKAGE
TECHNICAL PROCEDURES
GAS/WATER FUEL SYSTEM COMPONENTS
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 22
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 22 ...... 0
Alphabetical Index
Subject Page
Fuel Nozzle Installation .............................................................................................................. 6
Fuel Nozzle Removal.................................................................................................................. 4
Natural Gas Manifold Lower Section Installation ...................................................................... 16
Natural Gas Manifold Lower Section Removal.......................................................................... 15
Natural Gas Manifold Upper Section Installation....................................................................... 13
Natural Gas Manifold Upper Section Removal .......................................................................... 9
Natural Gas Supply Hose Installation......................................................................................... 8
Natural Gas Supply Hose Removal ............................................................................................ 7
Water Feeder Tube Installation ................................................................................................... 8
Water Feeder Tube Removal....................................................................................................... 8
Water Manifold Block Assembly................................................................................................ 21
Water Manifold Block Disassembly ........................................................................................... 21
Water Manifold Block Installation.............................................................................................. 22
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Alphabetical Index - Continued
Subject Page
Water Manifold Block Removal.................................................................................................. 19
Water Supply Hose Installation ................................................................................................... 9
Water Supply Hose Removal....................................................................................................... 9
Water Supply Manifold Installation ............................................................................................ 19
Water Supply Manifold Removal ................................................................................................ 18
1. Introduction.
This work package contains instructions for replacement of fuel nozzles, supply hoses, water
manifold, natural gas manifold, water manifold block, and associated components. (Reference
kit, PN 682L177.)
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Steam/Fuel Manifold Shipping Bracket Fixture Replacement WP 301500
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture Assembly, Shipping Bracket - 1C9381G01
Steam/Fuel Manifold
Fixture, Fuel Nozzle Mounting/Drilling 2C6883G01
Pliers, Teflon-Jawed Local Purchase
Sling, General Purpose Local Purchase
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GP460
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5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal L45921P01 2
Seal Ring 9016M30P02 30 (1 per
installed
fuel nozzle)
Seal Ring 9559M20G01/G02 (ALT)
Seal 9371M19P04 2
Seal 9371M19P104 (ALT)
Seal 9371M19P06 2
Seal 9371M19P106 (ALT)
Seal 9371M19P08 1
Seal 9371M19P10 4
Seal 9371M19P110 (ALT)
Seal 9371M19P12 3
Seal 9371M19P112 (ALT)
Seal, Inlet Flange Packager-Supplied 1
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6. Fuel Nozzle Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
NOTE
Various brackets may require removal with fuel nozzles. Ensure
brackets are tagged for location and orientation prior to
removal.
A. If replacing nozzle, remove cap from fuel nozzle primary circuit.
B. Disconnect natural gas supply hose from fuel nozzle (figure 1).
1
C. Loosen water feeder tube coupling nuts from water supply manifold.
CAUTION
Ensure fuel nozzle fittings are restrained when loosening coupling
nut. Failure to comply may result in part damage.
D. Disconnect water feeder tube from fuel nozzle.
E. Remove bolts that secure fuel nozzle onto compressor rear frame (CRF). Position
water feeder tube clear of fuel nozzle. Remove fuel nozzle and seal ring. Discard seal
ring.
F. If fuel nozzle bolt breaks during removal, use drilling fixture, 2C6883 (figure 2), to
remove broken bolt as follows:
(1) Position three lockscrews in unlocked position.
2
(2) Align drill bushing hole over broken bolt and align other two holes with tapped
holes in pad.
(3) Install two bolts through body and into tapped holes. Tighten bolts finger-tight.
(4) Turn three lockscrews and lock body to fuel nozzle hole.
(5) Select drill bushing size required and install in body.
(6) Drill broken bolt.
(7) Remove fixture.
4
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Figure 1. Fuel Nozzle, Feeder Tubes, and Hoses
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Figure 2. Fuel Nozzle Mounting/Drilling Fixture
(8) Remove broken bolt.
7. Fuel Nozzle Installation.
A. Install new seal ring onto fuel nozzle (figure 1).
CAUTION
Use care when installing fuel nozzles. Do not force fuel nozzles into
position. Failure to comply may result in fuel nozzle tip or swirl cup
damage.
B. Install fuel nozzle through CRF. Align seal ring with fuel nozzle boltholes.
C. Lubricate bolts with thread lubricant and install through fuel nozzle, seal ring, and
brackets, as required.
D. Tighten each fuel nozzle bolt to 50 lb in. (5.6 N·m) of torque, then tighten to
80-90 lb in. (9.0-10.2 N·m) of torque.
E. After 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in. (9.0-10.2 N·m) of
torque.
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F. After an additional 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in.
(9.0-10.2 N·m) of torque and safety-wire bolts in groups of three.
CAUTION
Ensure fuel nozzle fittings are restrained when tightening
coupling nut. Failure to comply may result in part damage.
G. Connect water feeder tube onto fuel nozzle center fitting and onto water supply
manifold.
H. Tighten coupling nut at fuel nozzle to 180-200 lb in. (20.3-22.6 N·m) of torque.
I. Tighten coupling nut at water supply manifold to 135-150 lb in. (15.3-16.9 N·m) of
torque.
J. Apply thread lubricant onto fuel nozzle outboard fitting threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
K. Connect natural gas supply hose onto fuel nozzle outboard fitting. Tighten coupling
nut as follows:
(1) Tighten coupling nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb
ft (106-125 N·m) of torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
L. If required, install cap onto fuel nozzle inboard fitting (primary circuit). Tighten cap to
135-150 lb in. (15.3-16.9 N·m) of torque and safety-wire.
8. Natural Gas Supply Hose Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect natural gas supply hose from natural gas manifold (figure 1).
B. Disconnect natural gas supply hose from fuel nozzle. Remove hose.
7
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9. Natural Gas Supply Hose Installation.
A. Apply thread lubricant onto natural gas supply hose coupling nut threads (figure 1).
B. Connect natural gas supply hose onto natural gas manifold and onto fuel nozzle
outboard fitting.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
C. Tighten hose coupling nuts as follows:
(1) Tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 78-92 lb
ft (106-125 N·m) of torque.
(3) Check nuts by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
10. Water Feeder Tube Removal.
A. Disconnect water feeder tube from water supply manifold (figure 1).
CAUTION
Ensure fuel nozzle fittings are restrained when loosening coupling
nut. Failure to comply may result in part damage.
B. Disconnect water feeder tube from fuel nozzle. Remove water feeder tube.
11. Water Feeder Tube Installation.
A. Connect water feeder tube onto fuel nozzle center fitting and onto water supply
manifold (figure 1).
CAUTION
Ensure fuel nozzle fittings are restrained when tightening
coupling nut. Failure to comply may result in part damage.
B. Tighten coupling nut at fuel nozzle to 180-200 lb in. (20.3-22.6 N·m) of torque. Install
water feeder tube.
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C. Tighten coupling nut at water supply manifold to 135-150 lb in. (15.3-16.9 N·m) of
torque. Install water feeder tube.
12. Water Supply Hose Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect water supply hose from water supply manifold (figure 1).
B. Disconnect water supply hose from water manifold block. Remove hose.
13. Water Supply Hose Installation.
A. Apply thread lubricant onto water supply hose coupling nut threads (figure 1).
B. Connect water supply hose onto appropriate water supply manifold fitting.
C. Connect water supply hose onto appropriate water manifold block fitting.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
D. Tighten water supply hose coupling nuts to 75-91 lb ft (102-123 N·m) of torque.
14. Natural Gas Manifold Upper Section Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect natural gas supply hoses from manifold upper section (figure 3).
3
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Figure3. Natural Gas and Water Manifolds (Sheet 1 of 2)
10
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Figure3. Natural Gas and Water Manifolds (Sheet 2 of 2)
NOTE
If fuel manifold inlet flange is located at 6:00 o'clock position,
disregard step B. If fuel manifold inlet flange is located at
12:00 o'clock position, disregard step C.
B. Remove bolts and nuts that secure manifold inlet 12 flange.
C. If manifold will be replaced, remove plug and seal. Discard seal.
11
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WARNING
• Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds
(37 kg). Ensure adequate personnel are available for manual
removal of manifolds. Failure to comply may result in engine
damage or serious injury.
• Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or
fall, they can cause an injury or kill you.
D. Install sling and 250-pound (113 kg) capacity hoist on manifold upper section, if
enclosure configuration permits. If sling and hoist cannot be installed, manifold
section must be removed manually.
E. Remove nuts, washers, and bolts from manifold section flanges.
NOTE
Removing or changing position of packager-supplied stanchion will
require use of steam/fuel manifold shipping bracket fixture assembly,
1C9381, to relocate natural gas manifold to proper position.
F. Disconnect packager-supplied mount braces from manifold upper section brackets.
G. Remove manifold upper section. Discard seal gaskets.
12
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15. Natural Gas Manifold Upper Section Installation.
WARNING
• Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or
fall, they can cause an injury or kill you.
• Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds
(37 kg). Ensure adequate personnel are available for manual
installation of manifolds. Failure to comply may result in
engine damage or serious injury.
CAUTION
• Do not deform hoses if lowering manifold lower section to gain
clearance for installation of manifold upper section. Failure to
comply may result in hose or fuel nozzle damage.
• If packager-supplied stanchions were moved, natural gas
manifold must be positioned with steam/fuel manifold shipping
bracket fixture assembly, 1C9381, per WP 301500. Failure to
comply can result in hose or fuel nozzle damage.
A. Install sling and 250-pound (113 kg) capacity hoist onto manifold upper section, if
enclosure configuration permits. If sling and hoist cannot be installed, manifold
section must be installed manually. Install upper manifold section.
B. Install three adjacent bolts through manifold section flanges. Install nuts and washers,
washers under nuts. Leave sufficient gap between flanges to insert gasket.
C. Install seal gasket between manifold section flanges (figure 3, detail A). Install five
remaining bolts through manifold section flanges. Install nuts and washers, washers
under nuts.
D. Tighten manifold section flange bolts and nuts to 220-250 lb in. (24.9-28.2 N·m) of
torque.
E. Connect packager-supplied mount braces onto upper manifold section brackets with
packager-supplied fasteners.
F. Tighten fasteners that secure packager-supplied mount braces onto upper manifold
section brackets to 480-570 lb in. (54.2-64.4 N·m) of torque.
13
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NOTE
If fuel manifold inlet flange is located at 6:00 o'clock position,
disregard steps G., H., and I.
G. Install three adjacent bolts through inlet flanges. Install nuts but leave sufficient gap
between flanges to insert gasket.
H. Install packager-supplied seal gasket between inlet flanges. Install five remaining bolts
through inlet flanges. Secure with nuts.
I. Tighten 12:00 o'clock position inlet flange bolts and nuts to 235-265 lb ft
(319-359 N·m) of torque.
NOTE
If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard steps J., and K.
J. Install seal onto plug.
K. Apply thread lubricant onto plug threads.
L. Install plug into manifold. Tighten plug to 450-550 lb in. (50.8-62.1 N·m) of torque.
M. Apply thread lubricant onto natural gas supply hose coupling nut threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
N. Connect natural gas supply hoses onto upper manifold. Tighten coupling nuts as
follows:
(1) Assemble and tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque at each
joint sequentially around in a clockwise direction aft looking forward (ALF).
(2) Loosen until coupling nut is free running and retighten to 78-92 lb
ft (106-125 N·m) of torque at each joint sequentially around in a clockwise
direction ALF.
(3) Check joint by reapplying 78-92 lb ft (106-125 N·m) of torque to the coupling nut
in the tightening direction at each joint sequentially around in a clockwise
direction ALF.
14
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16. Natural Gas Manifold Lower Section Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
A. Disconnect natural gas supply hoses from manifold lower section (figure 3).
NOTE
If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard step B. If fuel manifold inlet flange is located at 6:00
o'clock position, disregard step C.
B. Remove bolts and nuts that secure manifold inlet flange.
C. If manifold will be replaced, remove plug and seal. Discard seal.
NOTE
Removing or changing position of packager supplied stanchion
will require use of steam/fuel manifold shipping bracket fixture
assembly, 1C9381, to relocate natural gas manifold to proper
position.
D. Disconnect packager-supplied mount braces from manifold lower section brackets.
E. Remove nuts, washers, and bolts from manifold section flanges.
15
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WARNING
• Manifold section with inlet flange weighs 104 pounds
(47 kg). Manifold section without inlet flange weighs
81 pounds (37 kg). Ensure adequate personnel are avail-
able for manual removal of manifolds. Failure to comply
may result in engine damage or serious injury.
• Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts acciden-
tally move or fall, they can cause an injury or kill you.
CAUTION
Do not deform hoses if raising manifold upper section to gain
clearance for removal of manifold lower section. Failure to
comply may result in hose or fuel nozzle damage.
F. Remove manifold lower section. Discard seal gaskets.
17. Natural Gas Manifold Lower Section Installation.
WARNING
Manifold section with inlet flange weighs 104 pounds
(47 kg). Manifold section without inlet flange weighs
81 pounds (37 kg). Ensure adequate personnel are available
for manual installation of manifolds. Failure to comply may
result in engine damage or serious injury.
CAUTION
• Do not deform hoses if raising manifold upper section to gain
clearance for installation of manifold lower section. Failure to
comply may result in hose or fuel nozzle damage.
• If packager-supplied stanchions were moved, natural gas mani-
fold must be positioned with steam/fuel manifold shipping
bracket fixture assembly, 1C9381, per WP 301500. Failure to
comply can result in hose or fuel nozzle damage.
A. Manually install manifold lower section.
B. Install three adjacent bolts through manifold section flanges. Install nuts and washers,
washers under nuts. Leave sufficient gap between flanges to insert gasket.
16
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C. Install seal gaskets between manifold section flanges (figure 3, detail A). Install five
remaining bolts through manifold section flanges. Install nuts and washers, washers
under nuts.
D. Tighten manifold section flange bolts and nuts to 220-250 lb in. (24.9-28.2 N·m) of
torque.
E. Connect packager-supplied mount braces onto manifold lower section brackets with
packager-supplied fasteners.
F. Tighten bolts that secure packager-supplied mount braces onto manifold lower section
brackets to 480-570 lb in. (54.2-64.4 N·m) of torque.
NOTE
If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard steps G., H., and I.
G. Install three adjacent bolts through inlet flanges. Install nuts, but leave sufficient gap
between flanges to insert gasket.
H. Install packager-supplied seal gasket between inlet flanges. Install five bolts and nuts
through inlet flanges. Secure using nuts.
I. Tighten 6:00 o'clock position inlet flange bolts and nuts to 235-265 lb ft
(319-359 N·m) of torque.
NOTE
If fuel manifold inlet flange is located at 6:00 o'clock position,
disregard steps J. and K.
J. Install seal on plug.
K. Apply thread lubricant to plug threads.
L. Install plug into manifold. Tighten plug to 450-550 lb in. (50.8-62.1 N·m) of torque.
M. Apply thread lubricant to natural gas supply hose coupling nut threads.
17
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CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
N. Connect natural gas supply hoses onto lower manifold. Tighten coupling nuts as
follows:
(1) Assemble and tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque at each
joint sequentially around in a clockwise direction ALF.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque at each joint sequentially around in a clockwise
direction ALF.
(3) Check joint by reapplying 78-92 lb ft (106-125 N·m) of torque to the coupling nut
in the tightening direction at each joint sequentially around in a clockwise
direction ALF.
18. Water Supply Manifold Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect water supply hoses from water supply manifold (figure 3).
NOTE
Note location of section connectors to aid at assembly.
B. Remove nuts, bolts, and washers from water manifold section connectors.
C. If installed, remove clamps that secure water supply manifold to support brackets.
CAUTION
Ensure fuel nozzle fittings are restrained when loosening coupling
nut. Failure to comply may result in part damage.
D. Loosen water feeder tube coupling nuts from fuel nozzle.
E. Disconnect water feeder tube from water supply manifold. Remove water supply
manifold sections.
18
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19. Water Supply Manifold Installation.
A. Install one water manifold section onto appropriate water feeder tubes. Orient
manifold section connector as noted at removal. Do not tighten coupling nuts at this
time.
B. Connect remaining water manifold section onto installed manifold section. Secure
with bolts, nuts, and washers, washers under nuts. Tighten nuts finger-tight.
C. Connect remaining water feeder tubes onto water supply manifold. Tighten all water
feeder tube coupling nuts finger-tight.
D. Tighten water feeder tube coupling nuts at fuel nozzles to 180-200 lb in.
(20.3-22.6 N·m) of torque.
E. Tighten water feeder tube coupling nuts at water supply manifold to 135-150 lb in.
(15.3-16.9 N·m) of torque.
F. Tighten water supply manifold section connecting nuts to 55-70 lb in. (6.2-7.9 N·m) of
torque.
G. Apply thread lubricant onto water supply hose coupling nut threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
H. Install water supply hoses onto water supply manifold. Tighten water supply hose
coupling nuts to 75-91 lb ft (102-123 N·m) of torque.
I. If required, install clamps to secure water supply manifold onto support brackets.
20. Water Manifold Block Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
A. Disconnect water supply hoses from water supply adapters (figure 4).
4
B. Disconnect water supply inlet hose from water supply inlet adapter per packager's
manual.
C. Disconnect pressure sensing hose from pressure sensing adapter per packager's
manual.
19
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Figure 4. Water Manifold Block
20
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D. Disconnect electrical connectors from temperature sensors.
E. Remove bolts that secure water manifold block to bracket.
21. Water Manifold Block Disassembly.
CAUTION
Ensure water manifold block is secured in vise or other suitable
restraining device when removing adapters and temperature sen-
sors. Failure to comply may result in part damage.
A. Remove water supply inlet adapter. Remove and discard seal.
B. Remove pressure sensing adapter. Remove and discard seal.
C. Remove temperature sensors. Remove and discard seals.
D. Remove water supply adapters. Remove and discard seals.
E. Remove plugs. Remove and discard seals.
22. Water Manifold Block Assembly.
CAUTION
Ensure water manifold block is secured in vise or other suitable
restraining device when installing adapters and temperature sen-
sors. Failure to comply may result in part damage.
A. Install new seals onto water supply adapters. Install adapters into water supply ports.
Tighten adapters to 540-600 lb in. (61.0-67.8 N·m) of torque.
B. Install new seals onto temperature sensors. Install temperature sensors into
temperature sensor ports. Tighten sensors to 135-150 lb in. (15.3-16.9 N·m) of torque.
C. Install new seal onto pressure sensing adapter. Install adapter into pressure sensing
port. Tighten adapter to 180-200 lb in. (20.3-22.6 N·m) of torque.
D. Install new seal onto water supply inlet adapter. Install adapter into water supply inlet
port. Tighten adapter to 540-600 lb in. (61.0-67.8 N·m) of torque.
E. Install new seals onto primary fuel outlet port plugs. Install plugs into primary fuel
outlet ports. Tighten plugs to 360-400 lb in. (40.7-45.2 N·m) of torque.
F. Install new seal onto primary fuel pressure sensing port plug. Install plug into primary
fuel pressure sensing port. Tighten plug to 180-200 lb in. (20.3-22.6 N·m) of torque.
21
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G. Install new seal onto primary fuel inlet port plug. Install plug into primary fuel inlet
port. Tighten plug to 360-400 lb in. (40.7-45.2 N·m) of torque.
23. Water Manifold Block Installation.
A. Using bolts, install water manifold block onto bracket. Tighten bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
CAUTION
Ensure fuel manifold block adapters are restrained when tightening
coupling nuts. Failure to comply may result in part damage.
B. Connect electrical connectors to temperature sensors as follows:
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling back shell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
C. Apply thread lubricant to water supply hose coupling nut threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
D. Connect water supply hoses onto water supply adapters. Tighten coupling nuts to
75-91 lb ft (102-123 N·m) of torque.
E. Connect packager-supplied pressure sensing hose onto pressure sensing adapter.
Tighten coupling nut to 270-300 lb in. (30.5-33.9 N·m) of torque.
F. Connect water supply hose onto water supply inlet adapter. Tighten coupling nut to
75-91 lb ft (102-123 N·m) of torque.
22
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4WP 1513 00
WORK PACKAGE
TECHNICAL PROCEDURES
LIQUID FUEL/WATER FUEL SYSTEM COMPONENTS
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 20
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 20 ...... 0
Alphabetical Index
Subject Page
Fuel Feeder Tube Installation...................................................................................................... 7
Fuel Feeder Tube Removal ......................................................................................................... 7
Fuel Manifold Block Assembly .................................................................................................. 17
Fuel Manifold Block Disassembly.............................................................................................. 16
Fuel Manifold Block Installation ................................................................................................ 17
Fuel Manifold Block Removal.................................................................................................... 14
Fuel Nozzle Installation .............................................................................................................. 5
Fuel Nozzle Removal.................................................................................................................. 3
Fuel Supply Hose Installation ..................................................................................................... 9
Fuel Supply Hose Removal......................................................................................................... 8
Primary or Secondary Fuel Supply Manifold Installation .......................................................... 12
Primary or Secondary Fuel Supply Manifold Removal.............................................................. 10
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1. Introduction.
This work package contains instructions for replacement of fuel nozzles, supply hoses, liquid
fuel manifolds, fuel manifold block, and associated components. (Reference kit, PN 682L175.)
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture, Fuel Nozzle Mounting/Drilling 2C6883G01
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GP460
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Seal Ring 9016M30P02 AR
Seal 9371M19P04 2
Seal 9371M19P06 2
Seal 9371M19P10 3
Seal 9371M19P12 3
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6. Fuel Nozzle Removal.
WARNING
Fuel in liquid, vapor, or mist form is flammable, irritating
to the skin and respiratory tract, and poisonous in the diges-
tive tract. Remove saturated clothing, wash skin well, don't
swallow liquid, and don't breathe mist or vapor.
A. If required, remove brackets with fuel nozzles per SWP 1913 02. Tag brackets for
location and orientation prior to removal.
B. Remove cap from fuel nozzle if replacing nozzle. See figure 1.
1
C. Loosen primary and secondary fuel feeder tube coupling nuts from primary and
secondary fuel manifolds.
CAUTION
Ensure fuel nozzle fittings are restrained when loosening coupling
nut. Failure to comply may result in part damage.
D. Disconnect primary and secondary fuel feeder tubes from fuel nozzle.
E. Remove bolts that secure fuel nozzle onto compressor rear frame (CRF). Position fuel
feeder tubes clear of fuel nozzle. Remove fuel nozzle and seal ring. Discard seal ring.
F. If fuel nozzle bolt breaks during removal, use drilling fixture, 2C6883 (figure 2), to
remove broken bolt as follows:
(1) Position three lockscrews in unlocked position.
(2) Align drill bushing hole over broken bolt and align other two holes with tapped
holes in pad.
(3) Install two bolts through body and into tapped holes. Tighten bolts finger-tight.
(4) Turn three lockscrews and lock body to fuel nozzle hole.
(5) Select drill bushing size required and install in body.
(6) Drill broken bolt.
(7) Remove fixture.
(8) Remove broken bolt.
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Figure 1. Fuel Nozzles, Feeder Tubes, and Hoses
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2
Figure 2. Fuel Nozzle Mounting/Drilling Fixture
7. Fuel Nozzle Installation.
CAUTION
Fuel nozzles, PN L31476P49 (blue band), is installed at positions
4 and 27 (aft looking forward). For remaining positions, use fuel
nozzle, PN L31476P48(silver band). Do not mix fuel nozzles.
Failure to comply may result in engine damage.
A. Install new seal ring onto fuel nozzle. See figure 1.
CAUTION
Use care when installing fuel nozzles. Do not force fuel nozzles
into position. Failure to comply may result in fuel nozzle tip or
swirl cup damage.
B. Install fuel nozzle through CRF. Align seal ring with fuel nozzle boltholes.
C. Lubricate bolts with thread lubricant and install through fuel nozzle, seal ring, and
brackets, as required. See SWP 1913 02 for bracket installation.
5
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D. Tighten each fuel nozzle bolt to 50 lb in. (5.6 N·m) of torque, then tighten to
80-90 lb in. (9.0-10.2 N·m) of torque.
E. After 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in. (9.0-10.2 N·m) of
torque.
F. After an additional 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in.
(9.0-10.2 N·m) of torque and safety-wire bolts in groups of three.
CAUTION
Ensure fuel nozzle fittings are restrained when tightening
coupling nut. Failure to comply may result in part damage.
G. Connect primary fuel feeder tube onto fuel nozzle inboard fitting and onto primary
fuel supply manifold.
H. Tighten coupling nuts as follows:
(1) Tighten coupling nuts to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(3) Check nuts by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
I. Connect secondary fuel feeder tube onto fuel nozzle center fitting and onto secondary
fuel supply manifold.
J. Tighten coupling nut at fuel nozzle as follows:
(1) Tighten coupling nut to 180-200 lb in. (20.3-22.6 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 180-200 lb in.
(20.3-22.6 N·m) of torque.
(3) Check nut by reapplying 180-200 lb in. (20.3-22.6 N·m) of torque in the
tightening direction.
K. Tighten coupling nut at secondary fuel manifold as follows:
(1) Tighten coupling nut to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
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(3) Check nut by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
L. Install cap onto fuel nozzle outboard fitting, if required. Tighten cap to 75-91 lb ft
(102-123 N·m) of torque.
8. Fuel Feeder Tube Removal.
WARNING
• Fuel in liquid, vapor, or mist form is flammable, irritating to
the skin and respiratory tract, and poisonous in the digestive
tract. Remove saturated clothing, wash skin well, don't swal-
low liquid, and don't breathe mist or vapor.
• Fuel system is pressurized. Use care to prevent injury
when disconnecting lines.
A. Disconnect primary or secondary fuel feeder tube from fuel supply manifold.
See figure 1.
CAUTION
Ensure fuel nozzle fittings are restrained when loosening coupling
nut. Failure to comply may result in part damage.
B. Disconnect primary or secondary fuel feeder tube from fuel nozzle. Remove fuel
feeder tube.
9. Fuel Feeder Tube Installation.
CAUTION
Ensure fuel nozzle fittings are restrained when tightening
coupling nut. Failure to comply may result in part damage.
A. Connect primary fuel feeder tube onto fuel nozzle inboard fitting and onto primary
fuel supply manifold. See figure 1.
B. Tighten coupling nuts as follows:
(1) Tighten coupling nuts to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(3) Check nuts by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
7
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C. Connect secondary fuel feeder tube onto fuel nozzle center fitting and onto secondary
fuel supply manifold.
D. Tighten coupling nut at fuel nozzle as follows:
(1) Tighten coupling nut to 180-200 lb in. (20.3-22.6 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 180-200 lb in.
(20.3-22.6 N·m) of torque.
(3) Check nut by reapplying 180-200 lb in. (20.3-22.6 N·m) of torque in the
tightening direction.
E. Tighten coupling nut at secondary fuel supply manifold as follows:
(1) Tighten coupling nut to 135-150 lb in. (15.3-16.9 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(3) Check nut by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque in the
tightening direction.
10. Fuel Supply Hose Removal.
WARNING
• Fuel in liquid, vapor, or mist form is flammable, irritating to
the skin and respiratory tract, and poisonous in the digestive
tract. Remove saturated clothing, wash skin well, don't swal-
low liquid, and don't breathe mist or vapor.
• Fuel system is pressurized. Use care to prevent injury when
disconnecting lines.
CAUTION
Ensure flexible hose is restrained when loosening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
A. Disconnect primary or secondary fuel supply hose from fuel supply manifold.
See figure 1.
B. Disconnect primary or secondary fuel supply hose from fuel manifold block. Remove
hose.
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11. Fuel Supply Hose Installation.
A. Connect primary or secondary fuel supply hose to appropriate fuel supply manifold.
See figure 1.
B. Connect primary or secondary fuel supply hose to appropriate fuel manifold block
fitting.
C. Apply thread lubricant to fuel supply hose coupling nut threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
D. Tighten primary fuel supply hose coupling nuts as follows:
(1) Tighten coupling nuts to 55-65 lb ft (75-88 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to
55-65 lb ft (75-88 N·m) of torque.
(3) Check nuts by reapplying 55-65 lb ft (75-88 N·m) of torque in the tightening
direction.
E. Tighten secondary fuel supply hose coupling nuts as follows:
(1) Tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to
78-92 lb ft (106-125 N·m) of torque.
(3) Check nuts by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
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12. Primary or Secondary Fuel Supply Manifold Removal.
WARNING
• Fuel in liquid, vapor, or mist form is flammable, irritating to
the skin and respiratory tract, and poisonous in the digestive
tract. Remove saturated clothing, wash skin well, don't swal-
low liquid, and don't breathe mist or vapor.
• Fuel system is pressurized. Use care to prevent injury when
disconnecting lines.
CAUTION
Ensure flexible hose is restrained when loosening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
A. Disconnect primary or secondary fuel supply hoses from primary or secondary fuel
supply manifold. See figure 3.
3
NOTE
Note location of section connectors to aid at installation.
B. Remove bolts, nuts, and washers from primary or secondary manifold section
connectors.
C. Remove clamps that secure primary and secondary fuel supply manifolds together.
CAUTION
Ensure fuel nozzle fittings are restrained when loosening coupling
nut. Failure to comply may result in part damage.
D. Loosen primary or secondary fuel feeder tube coupling nuts from fuel nozzle.
E. Disconnect fuel feeder tube from primary or secondary fuel manifold. Remove
primary or secondary fuel supply manifold sections.
10
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Figure 3. Primary and Secondary Fuel Supply Manifolds (Sheet 1 of 2)
11
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Figure 3. Primary and Secondary Fuel Supply Manifolds (Sheet 2 of 2)
13. Primary or Secondary Fuel Supply Manifold Installation.
A. Install one primary or secondary fuel supply manifold section onto appropriate fuel
feeder tubes. Orient section connector as noted at disassembly. Do not tighten
coupling nuts at this time.
B. Connect remaining primary or secondary fuel supply manifold section to installed
manifold section. Secure with bolts, nuts, and washers, washers under nuts. Tighten
nuts finger-tight.
CAUTION
Ensure fuel manifolds are supported while attaching fuel feeder
tubes.
C. Connect remaining fuel feeder tubes onto fuel supply manifold. Tighten all fuel feeder
tube coupling nuts finger-tight.
D. Tighten primary feeder tube coupling nuts at fuel nozzles as follows:
(1) Assemble and tighten coupling nuts to 135-150 lb in. (15.3-16.9 N·m) of torque at
each joint sequentially around in a clockwise direction aft looking forward (ALF).
12
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(2) Loosen until coupling nut is free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque at each joint sequentially around in a clockwise
direction ALF.
(3) Check joint by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque to the
coupling nut in the tightening direction at each joint sequentially around in a
clockwise direction ALF.
E. Tighten secondary feeder tube coupling nuts at fuel nozzles as follows:
(1) Assemble and tighten coupling nuts to 180-200 lb in. (20.3-22.6 N·m) of torque at
each joint sequentially around in a clockwise direction ALF.
(2) Loosen until coupling nut is free running and retighten to 180-200 lb in.
(20.3-22.6 N·m) of torque at each joint sequentially around in a clockwise
direction ALF.
(3) Check joint by reapplying 180-200 lb in. (20.3-22.6 N·m) of torque to the
coupling nut in the tightening direction at each joint sequentially around in a
clockwise direction ALF.
F. Tighten primary and secondary feeder tube coupling nuts at primary or secondary fuel
supply manifold as follows:
(1) Assemble and tighten coupling nuts to 135-150 lb in. (15.3-16.9 N·m) of torque at
each joint sequentially around in a clockwise direction ALF.
(2) Loosen until coupling nut is free running and retighten to 135-150 lb in.
(15.3-16.9 N·m) of torque at each joint sequentially around in a clockwise
direction ALF.
(3) Check joint by reapplying 135-150 lb in. (15.3-16.9 N·m) of torque to the
coupling nut in the tightening direction at each joint sequentially around in a
clockwise direction ALF.
G. Tighten primary or secondary fuel supply manifold section connecting nuts as
follows:
(1) Tighten coupling nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 55-70 lb in.
(6.2-7.9 N·m) of torque.
(3) Check nuts by reapplying 55-70 lb in. (6.2-7.9 N·m) of torque in the tightening
direction.
13
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H. Apply thread lubricant to fuel supply hose coupling nut threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling
nut. Painted stripes on hose shall not be twisted. Failure to
comply may result in part damage.
I. Install primary or secondary fuel supply hoses onto appropriate fuel supply manifold.
Tighten primary fuel supply hose coupling nut as follows:
(1) Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 55-65 lb ft (75-88 N·m)
of torque.
(3) Check nut by reapplying 55-65 lb ft (75-88 N·m) of torque in the tightening
direction.
J. Tighten secondary fuel supply hose coupling nut as follows:
(1) Tighten nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until nut is free running and retighten to 78-92 lb ft (106-125 N·m) of
torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
K. Install clamps to hold primary and secondary fuel supply manifolds together.
14. Fuel Manifold Block Removal.
WARNING
• Fuel in liquid, vapor, or mist form is flammable, irritating to
the skin and respiratory tract, and poisonous in the digestive
tract. Remove saturated clothing, wash skin well, don't swal-
low liquid, and don't breathe mist or vapor.
• Fuel system is pressurized. Use care to prevent injury when
disconnecting lines.
A. Disconnect primary and secondary fuel supply hoses from fuel manifold block.
See figure 4.
4
B. Disconnect primary fuel inlet hoses from primary fuel inlet adapters per packager's
manual.
14
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Figure 4. Fuel Manifold Block
15
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C. Disconnect secondary fuel supply inlet and water supply inlet hoses from fuel inlet tee
fitting, if installed, per packager's manual.
D. Disconnect pressure sensing hoses from primary and secondary fuel supply inlet
pressure sensing adapters.
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
E. Tag and disconnect electrical connectors from primary and secondary fuel temperature
sensors.
F. Remove bolt and clamp that secure secondary fuel inlet tube onto bracket.
G. Remove bolts that secure fuel manifold block onto bracket. Remove fuel manifold
block.
15. Fuel Manifold Block Disassembly.
CAUTION
Ensure fuel manifold block is secured in vise or other suitable
restraining device when removing adapters and temperature sensors.
Failure to comply may result in part damage.
A. Disconnect secondary fuel inlet tube from secondary fuel inlet adapter. See figure 4.
B. Remove secondary fuel inlet adapter. Remove and discard seal.
C. Remove secondary fuel inlet pressure sensing adapter. Remove and discard seal.
D. Remove secondary fuel temperature sensor. Remove and discard seal.
E. Remove primary fuel inlet adapter. Remove and discard seal.
F. Remove primary fuel inlet pressure sensing adapter. Remove and discard seal.
G. Remove primary fuel temperature sensor. Remove and discard seal.
16
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H. Remove secondary fuel outlet adapters. Remove and discard seals.
I. Remove primary fuel outlet adapters. Remove and discard seals.
16. Fuel Manifold Block Assembly.
A. Install new seals onto secondary fuel outlet adapters. Install adapters into secondary
fuel outlet ports. Tighten adapters to 540-600 lb in. (61.0-67.8 N·m) of torque.
B. Install new seals onto primary fuel outlet adapters. Install adapters into primary fuel
outlet ports. Tighten adapters to 360-400 lb in. (40.7-45.2 N·m) of torque.
C. Install new seal onto primary fuel temperature sensor. Install sensor into primary fuel
temperature sensor port. Tighten sensor to 135-150 lb in. (15.3-16.9 N·m) of torque.
D. Install new seal onto primary fuel pressure sensing adapter. Install adapter into pri-
mary fuel pressure sensing port. Tighten adapter to 180-200 lb in. (20.3-22.6 N·m) of
torque.
E. Install new seal onto primary fuel inlet adapter. Install adapter into primary fuel inlet
port. Tighten adapter to 360-400 lb in. (40.7-45.2 N·m) of torque.
F. Install new seal onto secondary fuel temperature sensor. Install sensor into secondary
fuel temperature sensor port. Tighten sensor to 135-150 lb in. (15.3-16.9 N·m) of
torque.
G. Install new seal onto secondary fuel pressure sensing adapter. Install adapter into sec-
ondary fuel pressure sensing port. Tighten adapter to 180-200 lb in. (20.3-22.6 N·m)
of torque.
H. Install new seal onto secondary fuel inlet adapter. Install adapter into secondary fuel
inlet port. Tighten adapter to 540-600 lb in. (61.0-67.8 N·m) of torque.
I. Install secondary fuel inlet tube onto secondary fuel inlet adapter. Do not tighten cou-
pling nut at this time.
17. Fuel Manifold Block Installation.
A. Using bolts, install fuel manifold block onto bracket. Tighten bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
B. Using bolt, secure secondary fuel inlet tube clamp onto fuel manifold block mount
bracket. Tighten bolt to 55-70 lb in. (6.2-7.9 N·m) of torque.
17
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CAUTION
Ensure fuel manifold block adapters are restrained when
tightening coupling nuts. Failure to comply may result in part
damage.
C. Tighten secondary fuel inlet tube coupling nut as follows:
(1) Tighten coupling nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb
ft (106-125 N·m) of torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
D. Connect electrical connectors to primary and secondary fuel temperature sensors as
follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
E. Apply thread lubricant to fuel supply hose coupling nut threads.
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CAUTION
Ensure flexible hose is restrained when tightening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
F. Connect primary fuel supply hoses onto primary fuel supply adapters. Tighten
coupling nuts as follows:
(1) Tighten coupling nuts to 55-65 lb ft (75-88 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 55-65 lb ft
(75-88 N·m) of torque.
(3) Check nuts by reapplying 55-65 lb ft (75-88 N·m) of torque in the tightening
direction.
G. Connect secondary fuel supply hoses onto secondary fuel supply adapters. Tighten
coupling nuts as follows:
(1) Tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nuts by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
H. Connect packager-supplied primary and secondary fuel supply inlet pressure sensing
hoses onto primary and secondary fuel supply inlet pressure sensing adapters. Tighten
coupling nuts as follows:
(1) Tighten coupling nuts to 270-300 lb in. (30.5-33.9 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 270-300 lb in.
(30.5-33.9 N·m) of torque.
(3) Check nuts by reapplying 270-300 lb in. (30.5-33.9 N·m) of torque in the
tightening direction.
I. If required, connect water supply hose onto secondary fuel supply inlet tee fitting.
Tighten coupling nut to 75-91 lb ft (102-123 N·m) of torque.
19
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J. Connect primary fuel supply inlet hose onto primary fuel supply inlet adapter. Tighten
coupling nut as follows:
(1) Tighten coupling nut to 55-65 lb ft (75-88 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 55-65 lb ft (75-88 N·m)
of torque.
(3) Check nut by reapplying 55-65 lb ft (75-88 N·m) of torque in the tightening
direction.
K. Connect secondary fuel supply inlet hose onto secondary fuel supply inlet tee fitting.
Tighten coupling nut as follows:
(1) Tighten coupling nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
20
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4
WORK PACKAGE
TECHNICAL PROCEDURES
GAS FUEL SYSTEM COMPONENTS REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 14
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 14 ...... 0
Alphabetical Index
Subject Page
Fuel Nozzle Installation .............................................................................................................. 3
Fuel Nozzle Removal.................................................................................................................. 3
Natural Gas Manifold Lower Section Installation ...................................................................... 12
Natural Gas Manifold Lower Section Removal.......................................................................... 11
Natural Gas Manifold Upper Section Installation....................................................................... 9
Natural Gas Manifold Upper Section Removal .......................................................................... 7
Natural Gas Supply Hose Installation......................................................................................... 6
Natural Gas Supply Hose Removal ............................................................................................ 6
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1. Introduction.
This work package contains instructions for replacement of the fuel nozzles, supply hoses, and
natural gas manifold. (Reference kit, PN 682L176.)
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Steam/Fuel Manifold Shipping Bracket Fixture Replacement WP 3015 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture Assembly, Shipping Bracket - 1C9381G01
Steam/Fuel Manifold
Fixture, Fuel Nozzle Mounting/Drilling 2C6883G01
Sling, General Purpose Local Purchase
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GP460
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal L45921P01 2
Seal 9371M19P08 1
Seal Ring 9016M30P02 30 (1 per
installed
fuel nozzle)
Seal Ring 9559M20G01/G02 (ALT)
Seal, Inlet Flange Packager-Supplied 1
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6. Fuel Nozzle Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
NOTE
Various brackets may require removal with fuel nozzles. Ensure
brackets are tagged for location and orientation prior to removal.
A. Disconnect natural gas supply hose from fuel nozzle (figure 1).
B. Remove bolts that secure fuel nozzle onto compressor rear frame (CRF). Remove fuel
nozzle and seal ring. Discard seal ring.
1
C. If fuel nozzle bolt breaks during removal, use drilling fixture, 2C6883 (figure 2), to
remove broken bolt as follows:
(1) Position three lockscrews in unlocked position.
(2) Align drill bushing hole over broken bolt and align other two holes with tapped
holes in pad.
(3) Install two bolts through body and into tapped holes. Tighten bolts finger-tight.
(4) Turn three lockscrews and lock body to fuel nozzle hole.
(5) Select drill bushing size required and install in body.
(6) Drill broken bolt.
(7) Remove fixture.
(8) Remove broken bolt.
2
7. Fuel Nozzle Installation.
A. Install new seal ring onto fuel nozzle (figure 1).
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Figure1. Fuel Nozzles and Supply Hoses
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Figure2. Fuel Nozzle Mounting/Drilling Fixture
CAUTION
Use care when installing fuel nozzles. Do not force fuel nozzles into
position. Failure to comply may result in fuel nozzle tip or swirl cup
damage.
B. Install fuel nozzle through CRF. Align seal ring with fuel nozzle boltholes.
C. Lubricate bolts with thread lubricant and install through fuel nozzle, seal ring, and
brackets, as required.
D. Tighten each fuel nozzle bolt to 50 lb in. (5.6 N·m) of torque, then tighten to 80-90
lb in. (9.0-10.2 N·m) of torque.
E. After 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in. (9.0-10.2 N·m) of
torque.
F. After an additional 5 minutes, tighten fuel nozzle bolts again to 80-90 lb in.
(9.0-10.2 N·m) of torque and safety-wire bolts in groups of three.
G. Apply thread lubricant onto natural gas supply hose coupling nut threads.
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CAUTION
Ensure flexible hose is restrained when tightening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
H. Connect natural gas supply hose onto fuel nozzle fitting. Tighten coupling nut as
follows:
(1) Tighten coupling nut to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nut by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
8. Natural Gas Supply Hose Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
A. Disconnect natural gas supply hose from manifold (figure 1).
B. Disconnect natural gas supply hose from fuel nozzle. Remove hose.
9. Natural Gas Supply Hose Installation.
A. Apply thread lubricant onto natural gas supply hose coupling nut threads (figure 1).
B. Connect natural gas supply hose to manifold and onto fuel nozzle fitting.
CAUTION
Ensure flexible hose is restrained when tightening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
C. Tighten coupling nuts as follows:
(1) Tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque.
(2) Loosen until coupling nuts are free running and retighten to 78-92 lb ft
(106-125 N·m) of torque.
(3) Check nuts by reapplying 78-92 lb ft (106-125 N·m) of torque in the tightening
direction.
6
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10. Natural Gas Manifold Upper Section Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
A. Disconnect natural gas supply hoses from manifold upper section (figure 3).
3
NOTE
If fuel manifold inlet flange is located at 6:00 o'clock position, disregard
step B. If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard step C.
B. Remove bolts and nuts that secure manifold inlet flange.
C. If manifold will be replaced, remove manifold vent fitting and seal. Discard seal.
WARNING
• Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds (37
kg). Ensure adequate personnel are available for manual
removal of manifolds. Failure to comply may result in engine
damage or serious injury.
• Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or
fall, they can cause an injury or kill you.
D. Install sling and 250-pound (113 kg) capacity hoist on manifold upper section, if
enclosure configuration permits. If sling and hoist cannot be installed, manifold
section must be removed manually.
E. Remove nuts, washers, and bolts from manifold section mounting flanges.
NOTE
Removing or changing position of packager-supplied stanchions will
require use of steam/fuel manifold shipping bracket fixture assembly,
1C9381, to relocate natural gas manifold to proper position.
F. Remove packager-supplied mount braces from manifold upper section brackets.
G. Remove manifold upper section. Remove and discard seal gaskets.
7
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Figure3. Natural Gas Manifold
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11. Natural Gas Manifold Upper Section Installation.
WARNING
• Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds
(37 kg). Ensure adequate personnel are available for manual
installation of manifolds. Failure to comply may result in
engine damage or serious injury.
• Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or
fall, they can cause an injury or kill you.
CAUTION
• Do not deform hoses if lowering manifold lower section to gain
clearance for installation of manifold upper section. Failure to
comply may result in hose or fuel nozzle damage.
• If packager-supplied stanchions were moved, natural gas manifold
shall be positioned with steam/fuel manifold support bracket fixture
assembly, 1C9381, per WP 3015 00. Failure to comply may result in
hose or fuel nozzle damage.
A. Install sling and 250-pound (113 kg) capacity hoist onto manifold upper section, if
enclosure configuration permits. If sling and hoist cannot be installed, manifold
section must be installed manually. Install manifold upper section.
B. Install three adjacent bolts through upper and lower manifold section flanges
(figure 3). Install nuts and washers, washers under nuts. Leave sufficient gap between
flanges to insert gasket.
C. Install seal gaskets between manifold section flanges. Install five remaining bolts
through manifold section flanges. Install nuts and washers, washers under nuts.
D. Tighten manifold section flange nuts to 220-250 lb in. (24.9-28.2 N·m) of torque.
E. Install packager-supplied mount braces onto manifold upper section brackets with
packager-supplied fasteners.
F. Tighten fasteners that secure packager-supplied mount braces onto manifold upper
section brackets to 480-570 lb in. (54.2-64.4 N·m) of torque.
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NOTE
If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard steps G., H, and I.
G. Install three adjacent bolts through inlet flanges. Install nuts, but leave sufficient gap
between flanges to insert gasket.
H. Install packager-supplied seal gasket between inlet flanges. Install five remaining bolts
through inlet flanges and secure with nuts.
I. Tighten 12:00 o'clock position inlet flange nuts to 235-265 lb ft (319-359 N·m) of
torque, if required.
NOTE
If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard steps J and K
J. Install seal onto plug.
K. Apply thread lubricant onto plug threads.
L. Install plug into manifold. Tighten plug to 450-550 lb in. (50.8-62.1 N·m) of torque.
M. Apply thread lubricant onto natural gas supply hose coupling nut threads.
CAUTION
Ensure flexible hose is restrained when tightening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
N. Connect natural gas supply hoses onto manifold. Tighten coupling nuts as follows:
(1) Assemble and tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque at each
joint sequentially around in a clockwise direction aft looking forward (ALF).
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft
(106-125 N·m) of torque at each joint sequentially around in a clockwise direction
ALF.
(3) Check joint by reapplying 78-92 lb ft (106-125 N·m) of torque to the coupling nut
in the tightening direction at each joint sequentially around in a clockwise
direction ALF.
10
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12. Natural Gas Manifold Lower Section Removal.
CAUTION
Ensure flexible hose is restrained when loosening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
A. Disconnect natural gas supply hoses from manifold lower section (figure 3).
NOTE
If fuel manifold inlet flange is located at 12:00 o'clock position,
disregard step B. If fuel manifold inlet flange is located at 6:00
o'clock position, disregard step C.
B. Remove bolts and nuts that secure manifold inlet flange.
C. If manifold will be replaced, remove plug and seal. Discard seal.
D. Remove nuts, washers, and bolts from manifold section mounting flanges.
NOTE
Removing or changing position of packager-supplied stanchion
will require use of steam/fuel manifold shipping bracket fixture
assembly, 1C9381, to relocate natural gas manifold to proper
position.
E. Remove packager-supplied mount braces from manifold lower section brackets.
11
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WARNING
• Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds (37
kg). Ensure adequate personnel are available for manual
removal of manifolds. Failure to comply may result in engine
damage or serious injury.
• Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or
fall, they can cause an injury or kill you.
CAUTION
Do not deform hoses if raising manifold upper section to gain
clearance for removal of manifold lower section. Failure to comply
may result in hose or fuel nozzle damage.
F. Remove manifold lower section. Remove and discard seal gaskets.
13. Natural Gas Manifold Lower Section Installation.
WARNING
Manifold section with inlet flange weighs 104 pounds (47 kg).
Manifold section without inlet flange weighs 81 pounds (37 kg).
Ensure adequate personnel are available for manual installation
of manifolds. Failure to comply may result in engine damage or
serious injury.
CAUTION
• Do not deform hoses if raising manifold upper section to gain
clearance for installation of manifold lower section. Failure to
comply may result in hose or fuel nozzle damage.
• If packager-supplied stanchions were moved, natural gas
manifold shall be positioned with steam/fuel manifold support
bracket fixture assembly, 1C9381, per WP 3015 00. Failure to
comply may result in hose or fuel nozzle damage.
A. Manually install manifold lower section.
B. Install three adjacent bolts through manifold section flanges (figure 3). Install nuts and
washers, washers under nuts. Leave sufficient gap between flanges to insert gasket.
12
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C. Install seal gaskets between manifold section flanges. Install five remaining bolts
through manifold section flanges. Install nuts and washers, washers under nuts.
D. Tighten manifold section flange nuts to 220-250 lb in. (24.9-28.2 N·m) of torque.
E. Install packager-supplied mount braces onto manifold lower section brackets with
packager-supplied fasteners.
F. Tighten fasteners that secure packager-supplied mount braces onto manifold lower
section brackets to 480-570 lb in. (54.2-64.4 N·m) of torque.
NOTE
If fuel inlet manifold flange is located at 12:00 o'clock position,
disregard steps G., H., and I.
G. Install three adjacent bolts through inlet flanges. Install nuts, but leave sufficient gap
between flanges to insert gasket.
H. Install packager-supplied seal gasket between inlet flanges. Install remaining five
bolts through inlet flanges. Secure with nuts.
I. Tighten 6:00 o'clock position inlet flange nuts to 235-265 lb ft (319-359 N·m) of
torque, if required.
NOTE
If fuel manifold inlet flange is located at 6:00 o'clock position,
disregard steps J. and K.
J. Install seal onto plug.
K. Apply thread lubricant to plug threads.
L. Install plug into manifold. Tighten plug to 450-550 lb in. (50.8-62.1 N·m) of torque.
M. Apply thread lubricant onto natural gas supply hose coupling nut threads.
13
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CAUTION
Ensure flexible hose is restrained when tightening coupling nut.
Painted stripes on hose shall not be twisted. Failure to comply may
result in part damage.
N. Connect natural gas supply hoses onto manifold. Tightening coupling nuts as follows:
(1) Assemble and tighten coupling nuts to 78-92 lb ft (106-125 N·m) of torque at each
joint sequentially around in a clockwise direction ALF.
(2) Loosen until coupling nut is free running and retighten to 78-92 lb ft (106-125
N·m) of torque at each joint sequentially around in a clockwise direction ALF.
(3) Check joint by reapplying 78-92 lb ft (106-125 N·m) of torque to the coupling nut
in the tightening direction at each joint sequentially around in a clockwise|
direction ALF.
14
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 1515 00
3WP 1515 00
WORK PACKAGE
TECHNICAL PROCEDURES
ULTRAVIOLET FLAME SENSOR, FLAME SENSOR
SIGHT GLASS, AND FLAME SENSOR BRACKET
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-6 ...... 0
Alphabetical Index
Subject Page
Flame Sensor Bracket Installation .............................................................................................. 6
Flame Sensor Bracket Removal.................................................................................................. 5
Flame Sensor Sight Glass Installation ........................................................................................ 6
Flame Sensor Sight Glass Removal ............................................................................................ 6
Ultraviolet Flame Sensor Installation ......................................................................................... 3
Ultraviolet Flame Sensor Removal ............................................................................................. 3
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1515 00
1. Introduction.
A. If replacing flame sensor, L44819, or cooling can, L44821, go to SWP 1515 01.
B. This work package contains instructions for removal and installation of ultraviolet
flame sensor, L28490, flame sensor sight glass, and flame sensor bracket. Flame
sensors are located at the 4:00 o'clock and 10:00 o'clock positions.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Ultraviolet Flame Sensor, L44819, Flame Sensor Sight Glass,
and Flame Sensor Bracket Replacement SWP 1515 01
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket L43073P01 2
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 1515 00
6. Ultraviolet Flame Sensor Removal.
See figure 1.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
A. Disconnect flame sensor integral lead from packager's junction box per packager's
manual.
B. Remove bolts and clamps that secure flame sensor integral lead to brackets.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
C. Disconnect cooling air supply tube from cooling air fitting on cooling can.
D. Remove bolts that secure cooling can to flame sensor bracket. Slide cooling can up
onto integral lead.
E. Remove flame sensor. Remove and discard gasket.
1
7. Ultraviolet Flame Sensor Installation.
See figure 1.
A. Install new gasket and flame sensor onto flame sensor bracket.
B. Slide cooling can along integral lead over flame sensor. Secure cooling can and flame
sensor to flame sensor bracket with three bolts. Tighten bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
C. Connect cooling air supply tube onto cooling air fitting on cooling can. Tighten
coupling nut to 135-150 lb in. (15.3-16.9 N·m) of torque and safety-wire.
D. Install integral lead to brackets with clamps and bolts per SWP 1913 02. Tighten bolts
to 55-70 lb in. (6.2-7.9 N·m) of torque.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1515 00
Figure1. Ultraviolet Flame Sensor
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 1515 00
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
E. Connect flame sensor integral lead to packager's junction box per packager's manual.
8. Flame Sensor Bracket Removal.
See figure 2.
A. Remove flame sensor per paragraph 6.
B. Remove bolts that secure flame sensor bracket to support bracket. Remove flame
sensor bracket.
2
Figure2. Flame Sensor Sight Glass and Bracket
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1515 00
9. Flame Sensor Bracket Installation.
See figure 2.
A. Install flame sensor bracket and secure to support bracket with two bolts. Tighten bolts
to 55-70 lb in. (6.2-7.9 N·m) of torque.
B. Install flame sensor per paragraph 7.
10. Flame Sensor Sight Glass Removal.
See figure 2.
A. Remove ultraviolet flame sensor per paragraph 6.
B. Remove flame sensor bracket per paragraph 8.
C. Remove flame sensor sight glass from compressor rear frame.
11. Flame Sensor Sight Glass Installation.
See figure 2.
A. Install flame sensor sight glass into compressor rear frame. Tighten sight glass to
315-345 lb in. (35.6-39.0 N·m) of torque.
B. Install flame sensor bracket and secure to support bracket with two bolts. Tighten bolts
to 55-70 lb in. (6.2-7.9 N·m) of torque.
C. Install flame sensor per paragraph 7.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1515 01
3SWP 1515 01
SUBORDINATE WORK PACKAGE
TECHNICAL PROCEDURES
ULTRAVIOLET FLAME SENSOR, L44819, FLAME
SENSOR SIGHT GLASS, AND FLAME SENSOR
BRACKET REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-6 ...... 0
Alphabetical Index
Subject Page
Flame Sensor Bracket Installation .............................................................................................. 5
Flame Sensor Bracket Removal.................................................................................................. 5
Flame Sensor Sight Glass Installation ........................................................................................ 6
Flame Sensor Sight Glass Removal ............................................................................................ 5
Ultraviolet Flame Sensor Installation ......................................................................................... 3
Ultraviolet Flame Sensor Removal ............................................................................................. 3
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1515 01
1. Introduction.
This work package contains instructions for removal and installation of ultraviolet flame sensor,
L44819, flame sensor sight glass, and flame sensor bracket. Flame sensors are located at the
4:00 o'clock and 10:00 o'clock positions.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket L43073P01 2
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1515 01
6. Ultraviolet Flame Sensor Removal.
See figure 1.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
A. Disconnect interconnecting cable from packager's junction box per packager's manual.
B. Remove bolts and clamps that secure interconnecting cable to brackets.
C. Disconnect interconnecting cable from flame sensor.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
D. Disconnect cooling air supply tube from cooling air fitting on air cooling can.
E. Loosen adjustable clamp screws that secure cooling can to flame sensor. Slide cooling
can off flame sensor.
F. Remove flame sensor.
G. Remove three bolts that secure flame sensor tube mount onto flame sensor bracket.
Remove tube mount and gasket. Discard gasket.
1
7. Ultraviolet Flame Sensor Installation.
See figure 1.
A. Install gasket and flame sensor tube mount onto flame sensor bracket. Secure tube
mount to flame sensor bracket with three bolts. Tighten bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
B. Thread flame sensor onto tube mount. Hand-tighten flame sensor to until snug on tube
mount. Tighten flame sensor two and one-half turns.
C. Install cooling can onto flame sensor and tighten screws on adjustable clamps.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1515 01
Figure1. Ultraviolet Flame Sensor
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1515 01
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
D. Connect cooling air supply tube onto cooling air fitting on cooling can. Tighten
coupling nut to 135-150 lb in. (15.3-16.9 N·m) of torque and safety-wire.
E. Install interconnecting cable to brackets with clamps and bolts per SWP 1913 02.
Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
F. Connect interconnecting cable to packager's junction box per packager's manual.
G. Connect interconnecting cable to flame sensor.
8. Flame Sensor Bracket Removal.
See figure 2.
A. Remove flame sensor per paragraph 6.
B. Remove bolts that secure flame sensor bracket to support bracket. Remove flame
sensor bracket.
2
9. Flame Sensor Bracket Installation.
See figure 2.
A. Install flame sensor bracket and secure to support bracket with two bolts. Tighten
bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
B. Install flame sensor per paragraph 7.
10. Flame Sensor Sight Glass Removal.
See figure 2.
A. Remove ultraviolet flame sensor per paragraph 6.
B. Remove flame sensor bracket per paragraph 8.
C. Remove flame sensor sight glass from compressor rear frame.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1515 01
Figure2. Flame Sensor Sight Glass and Bracket
11. Flame Sensor Sight Glass Installation.
See figure 2.
A. Install flame sensor sight glass into compressor rear frame. Tighten sight glass to
315-345 lb in. (35.6-39.0 N·m) of torque.
B. Install flame sensor bracket and secure to support bracket with two bolts. Tighten bolts
to 55-70 lb in. (6.2-7.9 N·m) of torque.
C. Install flame sensor per paragraph 7.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 1516 00
5WP 1516 00
WORK PACKAGE
TECHNICAL PROCEDURES
IGNITER PLUG REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-7 ...... 4
8 Blank ...... 4
Alphabetical Index
Subject Page
Igniter Plug Inspection ................................................................................................................ 4
Igniter Plug Installation............................................................................................................... 4
Igniter Plug Removal .................................................................................................................. 3
Change 4 1
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1516 00
1. Introduction.
This work package contains instructions for removal and installation of the igniter plug.
NOTE
Two configurations exist: single igniter plug unit and double igniter plug unit.
Single igniter plugs are installed at the 3:00 o'clock position and a blank off
plug installed at the 5:00 o'clock position. With a double igniter plug unit,
igniter plugs are installed at the 3:00 and 5:00 o'clock positions.
2. Reference Material.
None required.
3. Support Equipment.
Nomenclature Part No.
Gage, Immersion Depth - Igniter Plug 2C6613G01
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
None required.
2 Change 4
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1516 00
6. Igniter Plug Removal.
WARNING
Ignition system shall be inoperative for at least 2 minutes before
disconnecting ignition leads. Ignition system could be charged
with lethal high voltage.
CAUTION
• Ensure igniter plug adapter is restrained when loosening coupling
nut. Failure to comply may result in part damage.
• Igniter plug may fall out when ignition lead is disconnected.
A. Disconnect ignition lead from igniter plug adapter. See figure 1. Momentarily ground
ignition lead to remove any residual electrical charge.
B. Remove igniter plug and shims.
1
Figure 1. Igniter Plug and Lead
Change 4 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1516 00
7. Igniter Plug Inspection.
A. Inspect igniter plug per table 1 and figure 2.
Table 1. Igniter Plug Inspection
On-Site Max On-Site Max
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Visible wear or None allowed Not repairable Inspect per step 2
grooving on plug
tip area
2. Depth of wear or Not exceeding Not repairable Replace plug
groove 0.015 in. (0.38 mm)
deep or less than
0.621 in. (15.77 mm)
diameter
2
8. Igniter Plug Installation.
A. Determine number of shims required as follows (figure 3):
(1) Measure from outer surface of igniter plug adapter to outer surface of combustor
ferrule using immersion depth gage, 2C6613. Record as dimension A.
(2) Refer to table 2 to determine number of shims required.
B. Install required number of shims on igniter plug.
C. Install igniter plug into igniter plug adapter. Ensure adapter is safety-wired. See figure 1.
CAUTION
Ensure igniter plug adapter is restrained when tightening coupling
nut. Failure to comply may result in part damage.
D. Install ignition lead over igniter plug adapter. Tighten coupling nut to 23.0-27.0 lb ft
(31.2-36.6 N·m) of torque.
CAUTION
Do not operate igniter unit with cap or cover in place. Failure to
comply may result in damage to part.
E. If installing a single igniter unit in place of a double igniter unit, ensure correct plug and
washer are installed. Apply thread lubricant to thread before installation. Tighten plug to
540-600 lb in. (61.1-67.8 N·m) of torque. Safety-wire blankoff plug. See figure 4.
4 Change 4
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1516 00
Figure 2. Igniter Plug Inspection
Change 4 5
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1516 00
3
Figure 3. Igniter Plug Immersion Depth
Table 2. Igniter Plug Shims Requirement.
Dimension A Number of Shims Required
2.177-2.208 inch (55.30-56.08 mm) 0
2.145-2.176 inch (54.48-55.27 mm) 1
2.113-2.144 inch (53.67-54.46 mm) 2
2.081-2.112 inch (52.86-53.64 mm) 3
2.048-2.080 inch (52.02-52.83 mm) 4
2.016-2.047 inch (51.21-51.99 mm) 5
1.984-2.015 inch (50.39-51.18 mm) 6
1.952-1.983 inch (49.58-50.37 mm) 7
1.920-1.951 inch (48.77-49.56 mm) 8
6 Change 4
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1516 00
Figure 4. Blankoff Plug Installed - Single Igniter System
Change 4 7/(8 Blank)
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1517 00
0WP 1517 00
WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR DISCHARGE
TEMPERATURE (T3) SENSOR REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 0
6 Blank ...... 0
Alphabetical Index
Subject Page
High Pressure Compressor Discharge Temperature (T3) Sensor Installation ............................ 3
High Pressure Compressor Discharge Temperature (T3) Sensor Removal ................................ 3
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1517 00
1. Introduction.
This work package contains instructions for removing and installing the high pressure
compressor (HPC) discharge temperature (T3) sensor. For detailed routing and clamping, see
SWP 1913 02.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Core Module External Tubing, Electrical Leads, and SWP 1913 02
Clamping
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket MS9202-042 1
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1517 00
6. High Pressure Compressor Discharge Temperature (T3) Sensor Removal.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure that location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
A. Tag and disconnect electrical connector from T3 sensor integral lead. See figure 1.
1
B. Remove jamnut that secures T3 sensor integral lead to No. 3 electrical interface panel.
C. Remove bolts that secure T3 sensor integral lead clamps to brackets. Remove clamps
from T3 sensor integral lead.
D. Remove bolts and washers that secure T3 sensor to high pressure compressor (HPC)
rear frame mounting boss.
E. Remove T3 sensor and gasket. Discard gasket.
7. High Pressure Compressor Discharge Temperature (T3) Sensor Installation.
See figure 1.
A. Install new gasket, P/N MS9202-042, and T3 sensor onto HPC rear frame mounting
boss. Forward (FWD) marking on T3 sensor must face toward front of engine.
NOTE
Maintain 5 inches (127 mm) minimum bend radius during
routing of T3 sensor integral lead.
B. Using four washers and bolts, secure T3 sensor onto HPC rear frame. Tighten bolts
to 55-70 lb in. (6.3-7.9 N·m) of torque. Safety-wire bolts.
C. Install clamps onto T3 sensor integral lead.
D. Secure clamps onto brackets using bolts. Tighten bolts to 55-70 lb in. (6.3-7.9 N·m)
of torque.
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1517 00
Figure1. High Pressure Compressor Discharge Temperature (T3) Sensor
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WP 1517 00
E. Secure T3 sensor integral lead to No. 3 electrical interface panel with jamnut. Tighten
jamnut to 25-35 lb in. (2.9-3.9 N·m) of torque. Safety-wire jamnut.
F. Connect electrical connector to T3 sensor integral lead as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
5/(6 Blank)
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 1518 00
0WP 1518 00
WORK PACKAGE
TECHNICAL PROCEDURES
COMPRESSOR DISCHARGE PRESSURE (CDP)
BLEED AIR MANIFOLD AND FLANGE COVER
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-6 ...... 0
Alphabetical Index
Subject Page
Compressor Discharge Pressure (CDP) Bleed Air Manifold Installation................................... 6
Compressor Discharge Pressure (CDP) Bleed Air Manifold Removal ...................................... 3
Compressor Discharge Pressure (CDP) Flange Cover Installation............................................. 3
Compressor Discharge Pressure (CDP) Flange Cover Removal ................................................ 3
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1518 00
1. Introduction.
This work package contains instructions for removing and installing compressor discharge
pressure (CDP) bleed air manifold (Reference kit, P/N 682L196G01) and cover plate. The cover
plate caps off CDP bleed air at 3 locations on the compressor rear frame. No cap is available to cap
the end of the bleed air manifold.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
None required.
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Ring, Seal - Metal J1128P05 3
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WP 1518 00
6. Compressor Discharge Pressure (CDP) Bleed Air Manifold Removal.
See figure 1.
A. Disconnect CDP discharge pipe from customer interface per packager's manual.
B. Remove V-band clamps that secure air manifold to CDP discharge ports.
C. Remove nuts, washers, and bolts that secure clamp to upper air manifold bracket.
Remove clamp.
D. Remove nuts, washers, and bolts that secure clamp to lower air manifold bracket.
Remove clamp.
E. Remove nuts, washers, and bolts that secure two clamps to CDP discharge pipe
bracket. Remove clamps, air manifold, and seal rings. Discard seal rings.
1
7. Compressor Discharge Pressure (CDP) Flange Cover Removal.
See figure 2.
A. If installed, remove three V-band clamps, CDP flange covers, and seal rings. Discard
seal rings.
2
8. Compressor Discharge Pressure (CDP) Flange Cover Installation.
See figure 2.
A. Install three new seal rings, P/N J1128P05, and CDP flange covers onto CDP
discharge ports using V-band clamps.
B. Tighten nuts on V-band clamps to 75-90 lb in. (8.5-10.1 N·m) of torque.
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WP 1518 00
Figure 1. CDP Bleed Air Manifold
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WP 1518 00
Figure 2. CDP Flange Cover
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WP 1518 00
9. Compressor Discharge Pressure (CDP) Bleed Air Manifold Installation.
See figure 1.
A. Install new seal rings, P/N J1128P05, and air manifold onto CDP discharge ports.
Using clamps, bolts, washers, and nuts, secure air manifold onto CDP discharge pipe
bracket. Washers under nuts. Tighten nuts finger-tight.
B. Secure air manifold onto CDP discharge ports with V-band clamps. Tighten nuts on
V-band clamps to 75-90 lb in. (8.5-10.1 N·m) of torque.
C. Using bolts, washers, and nuts, install upper air manifold bracket clamp, washers
under nuts. Tighten nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
D. Using bolts, washers, and nuts, install lower air manifold bracket, washers under nuts.
Tighten nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
E. Tighten CDP discharge pipe bracket clamp nuts to 55-70 lb in. (6.3-7.9 N·m) of
torque.
F. Connect CDP discharge pipe to customer interface per packager's manual.
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WP 1710 00
5WP 1710 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE ROTOR SPEED (XNSD) SENSOR
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-7 ...... 4
8 Blank ...... 4
Alphabetical Index
Subject Page
Low Pressure Rotor Speed (XNSD) Sensor Installation ............................................................ 6
Low Pressure Rotor Speed (XNSD) Sensor Removal ................................................................ 3
Change 4 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1710 00
1. Introduction.
This work package contains instructions for removing and installing the low pressure rotor speed
(XNSD) sensor. There are two XNSD sensors on the low pressure turbine (LPT) rotor, one at 2:30
o'clock position, and one at 9:30 o'clock position. For detailed routing and clamping, see
SWP 1913 03.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Turbine (LPT) Module External Tubing, Har-
nesses, and Clamping SWP 1913 03
Illustrated Parts Breakdown GEK 105060
Safety-Wiring of Low Pressure Rotor Speed (XNSD) Sensor
Electrical Connector (PA Uprate, PC, and PD Models) LM6000-IND-165
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Petrolatum Fed Spec VV-P-236
Safety Cable 736L680G01
Safety Wire R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed 2435M99P01 4
2 Change 4
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WP 1710 00
6. Low Pressure Rotor Speed (XNSD) Sensor Removal.
NOTE
Turbine rear frame (TRF) insulation blankets are no longer required
and can be removed and discarded.
A. If installed, remove insulation blankets as follows:
(1) Remove bolt and nut securing strap around blankets, and remove strap. Discard
strap.
(2) Remove bolts, nuts, and washers attaching insulation brackets to TRF aft flange.
Discard brackets.
(3) Remove safety wire securing blankets together at three locations.
(4) Remove all insulation blankets from TRF. Discard blankets.
(5) Reinstall bolt, washer, and nut attaching electrical bracket to TRF aft flange at
4:30 o’clock position. Tighten nut to 190-230 lb in. (21.5-26.0 N·m) of torque.
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
B. Tag and disconnect electrical connector from XNSD sensor. See figure 1.
1
WARNING
Use extreme care when working with springs under com-
pression. Serious injury could result if spring is suddenly
released.
C. If Service Bulletin LM6000-IND-165 has been accomplished, remove safety wire
from bolt. Remove nut and bolt that secure clamp to bracket. Remove clamp from
XNSD sensor.
D. Remove nuts and bolts that secure bracket and spring retainer to adapter strut.
E. Remove bracket, spring retainer, and spring from adapter strut.
Change 4 3
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WP 1710 00
Figure 1. Low Pressure Rotor Speed (XNSD) Sensor
4 Change 4
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CAUTION
Shim spacers must be separated or pulled away from XNSD sensor
to allow removal of sensor, or damage to sensor will occur.
F. Loosen four bolts and nuts attaching adapter strut to TRF strut. Do not remove bolts
and nuts.
G. Pull XNSD sensor out about 0.25 inch (6.4 mm).
H. Pull shim spacers, located between adapter strut and TRF strut, out as far as possible.
Shim spacers are not removable. See figure 2
CAUTION
Use care when removing sensor to avoid damage to sensor tip.
I. Pull XNSD sensor straight out of strut.
J. Remove and discard preformed packings from sensor tip.
2
Figure 2. Shim Spacers Pulled Out for XNSD Sensor Removal/Installation
Change 4 5
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WP 1710 00
7. Low Pressure Rotor Speed (XNSD) Sensor Installation.
CAUTION
Use care when installing sensor to avoid damage to sensor tip.
A. Lubricate new preformed packings with petrolatum and install onto XNSD sensor.
See figure 1.
B. Ensure shim spacers, located between adapter strut and TRF strut, are pulled out as
far as possible or sensor cannot be installed. See figure 2.
C. Slide XNSD sensor straight down into strut.
D. Slide shim spacers together around XNSD sensor and secure with four bolts and nuts.
Tighten nuts to 100-130 lb in. (11.3-14.7 N·m) of torque.
E. Install spring onto XNSD sensor. See figure 1.
NOTE
Pressure must be kept on spring retainer until nuts are tight-
ened.
F. Install spring retainer and bracket onto adapter strut and secure with bolts and nuts.
Tighten nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
G. Connect electrical connector (4, figure 3) to XNSD sensor as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
NOTE
It may be necessary to loosen lead clamps that restrict seating
of electrical connector.
(1) Engage connector with mating sensor connector and turn knurled coupling
ring (5) while wiggling backshell assembly.
(2) Fully seat connector (4) by hand. Tighten coupling ring (5) using Teflon-jawed
pliers. Tighten connector 1/4-1/2 turn beyond finger-tight.
6 Change 4
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WP 1710 00
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
(4) Repeat substeps (2) and (3) as required, to ensure electrical connector (4) is
seated.
H. Install clamp (3) onto bracket. Secure clamp to bracket with bolt (1) and existing nut
(2). Tighten nut to 55-70 lb in. (6.2-7.9 N·m) of torque.
I. If Service Bulletin LM6000-IND-165 has been accomplished, safety-wire knurled
coupling ring (5) to new bolt (1).
3
Figure 3. XNSD Sensor
Change 4 7/(8 Blank)
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WP 1711 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE TURBINE INLET TEMPERATURE
(T48) THERMOCOUPLE REPLACEMENT/INSPECTION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 2
Alphabetical Index
Subject Page
Low Pressure Turbine Inlet Temperature (T48) Thermocouple Inspection................................ 3
Low Pressure Turbine Inlet Temperature (T48) Thermocouple Installation .............................. 8
Low Pressure Turbine Inlet Temperature (T48) Thermocouple Removal.................................. 3
Change 2 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1711 00
1. Introduction.
This work package contains instructions for removal, inspection, and installation the low
pressure turbine (LPT) inlet temperature (T48) thermocouple. Refer to SWP 1913 03 for routing
of T48 harnesses.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Turbine (LPT) Module External Tubing, Har- SWP 1913 03
nesses, and Clamping
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Deleted
Fixture, Puller-Exhaust Gas Temperature 9429M49G01
Probe
Heat Gun Local Purchase
4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
Thread Lubricant GP 460
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket 9379M93P01 8
2 Change 2
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WP 1711 00
6. Low Pressure Turbine Inlet Temperature (T48) Thermocouple Removal.
See figure 1.
A. Loosen nuts that secure thermocouple harness to T48 thermocouple. Disconnect
hermocouple harness from T48 thermocouple.
B. Remove bolts that secure T48 thermocouple to LPT case. Remove T48 thermocouple.
C. Use puller fixture, 9429M49, if probe is difficult to remove. See figure 1A.
D. Remove and discard gasket.
7. Low Pressure Turbine Inlet Temperature (T48) Thermocouple Inspection.
A. Inspect thermocouples per table 1 and figure 2.
2
1
B. Preferred method of measuring insulation resistance:
(1) Heat probe in oven at 400°F (204°C) for 1 hour.
WARNING
Wear insulated gloves to prevent injury when handling hot
parts.
(2) Place probe into a container of demineralized water. Ensure water fills inside of
all cavities.
(3) Remove temperature probe from water and dry for 5 minutes in air, heating to
00 to 300°F (93.3 to 148.9°C) using heat gun.
(4) Individually measure resistance, using hi-pot megohmmeter, of each threaded
stud to probe body.
C. Alternate method of measuring insulation resistance:
(1) Place probe in a container of demineralized water. Ensure water fills inside of all
cavities.
(2) Individually measure resistance, using ohmmeter, of each threaded stud to probe
body.
Change 2 3
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WP 1711 00
Figure 1. Low Pressure Turbine Inlet Temperature (T48) Thermocouple
4 Change 2
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WP 1711 00
Figure 1A. Temperature Probe Puller Fixture, 9429M49
Change 2 5
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WP 1711 00
Table 1. Thermocouple Inspection Criteria
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Support and Sheath for:
a. Corrosion/oxida- 0.228 inch (5.8 mm) Not repairable Replace probe
tion diameter at mid point
inlet gas port
b. Missing material None allowed Not repairable Replace probe
(including tip)
c. Bowed support 0.090 inch (2.29 mm) Not repairable Replace probe
at end of support
d. Cracks None allowed Not repairable Replace probe
2. Electrical Circuitry for: (thermocouple elements)
WARNING
Alcohol is flammable and toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid
repeated or prolonged contact. Use in a well-ventilated
area.
NOTE
Clean probe with clean cloth and alcohol. Dry with jet of dry,
filtered compressed air. Disconnect electrical harness. Mea-
sure resistance with one ohmmeter lead on each threaded stud,
then reverse ohmmeter leads and average resistance values.
a. KP to KN circuit 2.4 to 4.1 ohms Not repairable Replace probe
resistance
b. Insulation resis- >10 Mohms each Not repairable Replace probe
tance (refer to
steps B. and C.)
6 Change 2
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WP 1711 00
Figure 2. Low Pressure Turbine Inlet Temperature (T48) Thermocouple Inspection
Change 2 7
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8. Low Pressure Turbine Inlet Temperature (T48) Thermocouple Installation.
See figure 1.
A. Install new gasket, P/N 9379M93P01, onto LPT case.
B. Install T48 thermocouple into LPT case with flat side of flange facing aft. Using
thread lubricant, lubricate threads and friction surfaces of bolts and secure thermocou-
ple with bolts. Tighten bolts to 90-100 lb in. (10.1-11.3 N·m) of torque.
C. Ensure curved spring washer is in place, and connect thermocouple harness to T48
thermocouple and secure with nuts.
CAUTION
Do not over tighten thermocouple harness nuts. Failure to comply
may result in part damage.
D. Tighten largest diameter nut to 29-33 lb in. (3.3-3.7 N·m) of torque. Tighten smallest
diameter nut to 16-18 lb in. (1.8-2.0 N·m) of torque.
8 Change 2
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WP 1712 00
5WP 1712 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE TURBINE INLET PRESSURE (P48)
PROBE REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-4 ...... 4
Alphabetical Index
Subject Page
Low Pressure Turbine Inlet Pressure (P48) Probe Inspection .................................................... 3
Low Pressure Turbine Inlet Pressure (P48) Probe Installation ................................................... 4
Low Pressure Turbine Inlet Pressure (P48) Probe Removal....................................................... 3
Change 4 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1712 00
1. Introduction.
This work package contains instructions for removing and installing the low pressure turbine
(LPT) inlet pressure (P48) probe.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol Fed Spec. TT-I-735
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket 1538M42P01 1
Gasket 1538M42P02 (ALT)
2 Change 4
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WP 1712 00
6. Low Pressure Turbine Inlet Pressure (P48) Probe Removal.
A. Disconnect pressure sensing tube from P48 pressure probe. See figure 1.
B. Remove safety wire. Remove bolts and washers that secure P48 probe onto LPT
case. Remove P48 probe.
C. Remove and discard gasket.
7. Low Pressure Turbine Inlet Pressure (P48) Probe Inspection.
A. Clean probe using isopropyl alcohol to remove external dirt. Total probe immersion
is permitted.
B. Inspect probe per table 1 and figure 1.
Table 1. LPT Pressure Probe
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Sheath Area for:
a. Corrosion/ Minimum 0.223 inch Not repairable Replace probe
oxidation (5.66 mm) diameter at
gas port inlet
b. Missing None allowed Not repairable Replace probe
material
(including tip)
c. Bowed support 0.090 inch (2.29 mm) Not repairable Replace probe
at end of support
d. Cracks None allowed Not repairable Replace probe
2. Probe Sensing Holes for:
a. Hole diameters 0.045-0.048 inch (1.14- Not repairable Replace probe
1.22 mm) diameter
b. Blockage None allowed Not repairable Replace probe
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8. Low Pressure Turbine Inlet Pressure (P48) Probe Installation.
A. Install new gasket, P/N 1538M42P01, onto LPT case. See figure 1.
B. Install P48 pressure probe in LPT case so that holes in probe face forward. Secure
probe with two washers and bolts. Tighten bolts to 55-70 lb in. (6.3-7.9 N·m) of
torque. Safety-wire bolts.
C. Connect pressure sensing tube to P48 probe per packager's manual.
1
Figure 1. Low Pressure Turbine Inlet Pressure (P48) Probe
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WP 1713 00
0WP 1713 00
WORK PACKAGE
TECHNICAL PROCEDURES
THRUST BALANCE VALVE (TBV) ASSEMBLY
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 0
Alphabetical Index
Subject Page
Thrust Balance Valve (TBV) Assembly Installation................................................................... 6
Thrust Balance Valve (TBV) Assembly Removal ...................................................................... 3
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WP 1713 00
1. Introduction.
This work package contains instructions for removing and installing the thrust balance valve
(TBV) assembly, including changing orifices.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
E-Seal 2873-400 2
Seal Ring, Metal J1128P24 2
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6. Thrust Balance Valve (TBV) Assembly Removal.
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
CAUTION
Ensure that location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
A. Tag and disconnect electrical connector from TBV assembly.
B. Disconnect tubing from TBV assembly as follows (figure 1):
1
(1) Position a waste fluid container beneath TBV assembly.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do
not inhale, ingest, or let this material touch you. Irritant.
Personal protective equipment required. Use mechanical
exhaust ventilation - if not available, use an approved respi-
rator.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
(2) Disconnect drain tube coupling nut from TBV valve fitting.
(3) Disconnect supply tube and return tube coupling nuts from TBV assembly
fittings.
C. Disconnect packager supplied piping connections to TBV assembly inlet, discharge,
and bypass connections per packager instructions. Discard bypass seal rings and
E-seal (7). Handle bypass orifice plate (1) with care to prevent damage to orifice.
D. Remove four bolts that secure TBV assembly to mounting bracket. Remove TBV
assembly.
E. Disassemble TBV assembly as follows:
(1) Matchmark flange tee (2), flange to V adapter (9), and bleed air valve (8) flanges
for reassembly.
3
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Figure1. TBV Assembly (Sheet 1 of 2)
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Figure1. .TBV Assembly (Sheet 2 of 2)
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(2) Remove V-band clamp connecting bleed air valve (8) to flange to V adapter (9).
Discard E-seal (7).
(3) Remove eight nuts (4) and bolts (3) that secure flange to V adapter (9) to flange
tee (2). Discard metal seal rings (5). Handle main orifice plate (6) with care to
prevent damage to orifice.
7. Thrust Balance Valve (TBV) Assembly Installation.
A. Assemble TBV assembly as follows (figure 1, sheet 2):
(1) Lubricate threads and washer faces of eight bolts (3) with thread lubricant. Install
bolts thorough boltholes in flange tee (2).
NOTE
Chamfered side of orifice in orifice plate faces away from
flange on flange tee.
(2) Install new metal seal ring (5), orifice plate (6) [with chamfered side of orifice
away from flange tee (2)], and new metal seal ring (5) over bolts (3) onto flange
tee (2) flange face.
(3) Use matchmarks (if present) to align flange to V adapter (9) to flange tee (2).
Install flange to V adapter over bolts (3) and seat on metal seal rings (5) and
orifice plate (6). Secure assembly with nuts.
(4) Tighten nuts in crisscross pattern to 33-37 lb in. (3.8-4.1 N·m) of torque.
(5) Install new E-seal (7) onto inlet flange of bleed air valve (8).
(6) Use matchmarks (if present) to align V flange of flange to V adapter (9) to inlet
flange of bleed air valve (8). Seat flange to V adapter onto bleed air valve and
secure with packager supplied V-band type clamp as follows:
(a) Tighten clamp nut to approximately 60 lb in. (6.8 N·m) of torque. Check to
ensure clamp is seated over flanges equally around circumference, and E-seal
is properly seated. Loosen clamp and reseat as necessary.
(b) Using soft-faced mallet, lightly tap around circumference of clamp to seat
evenly.
(c) Continue to tap around clamp to ensure even seating, and tighten clamp nut
to 115-125 lb in. (13.0-14.1 N·m) of torque.
(d) Tap around circumference of clamp. Retighten nut to 115-125 lb in.
(13.0-14.1 N·m) of torque.
6
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NOTE
Preferred orientation of valve is shown on sheet 2.
B. Install TBV assembly on mounting bracket and secure with packager-supplied bolts.
Tighten bolts to 100-130 lb in. (11.3-14.6 N·m) of torque.
C. Connect TBV assembly inlet per packager instructions and as follows
(figure 1, sheet 1):
(1) Install new packager-supplied seal ring onto flange of flange tee.
(2) Align packager-supplied high pressure compressor stage 11 tube flange to flange
tee and install packager-supplied bolts. Ensure seal is properly seated. Install nuts
onto bolts and tighten in crisscross pattern to 100-130 lb in. (11.3-14.6 N·m) of
torque.
D. Connect TBV assembly outlet per packager instructions and as follows:
(1) Install new E-seal (7) onto outlet flange of bleed air valve (8).
(2) Align packager-supplied thrust balance interface tube to bleed air valve (8).
Secure tube onto valve with packager-supplied V-band type clamp as follows:
(a) Tighten clamp nut to approximately 60 lb in. (6.8 N·m) of torque. Check to
ensure clamp is seated over flanges equally around circumference, and E-seal
(7) is properly seated. Loosen clamp and reseat as necessary.
(b) Using soft-faced mallet, lightly tap around circumference of clamp to seat
clamp evenly.
(c) Continue to tap around clamp to ensure even seating, and tighten clamp nut
to 115-125 lb in. (13.0-14.1 N·m) of torque.
(d) Tap around circumference of clamp. Retighten nut to 115-125 lb in.
(13.0-14.1 N·m) of torque.
E. Connect TBV assembly bypass per packager instructions as follows:
NOTE
Chamfered side of orifice in orifice plate faces away from
flange on flange tee.
(1) Install packager-supplied seal ring, orifice plate (1) [with chamfered side of
orifice away from flange tee (2)], and new packager-supplied seal ring onto
flange T flange face.
7
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WP 1713 00
(2) Align packager-supplied bypass tube onto flange T flange face. Secure with
packager-supplied bolts and nuts. Ensure seals and orifice plate are properly
seated.
(3) Tighten nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
F. Align and connect packager-supplied supply tube, return tube, and drain tube onto
bleed air valve (8) fittings. Tighten coupling nuts as follows:
(1) Tighten return tube coupling nut to 270-300 lb in. (30.6-33.9 N·m) of torque.
(2) Tighten drain tube coupling nut to 450-550 lb in. (50.9-62.1 N·m) of torque.
(3) Tighten supply tube coupling nut to 135-150 lb in. (15.3-16.9 N·m) of torque.
G. Check supply, return, and drain connections for leakage per packager instructions.
H. Connect electrical cable as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Align and install cable harness connector onto bleed air valve receptacle. Turn
coupling ring while wiggling the back shell assembly.
(2) After seating connector by hand, tighten the coupling ring using Teflon-jawed
pliers. Tighten 1/4-1/2 turn, or until pliers slip on coupling ring.
(3) Check for full seating by wiggling the connector assembly. No movement
between mating connectors is allowed.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
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WP 1714 00
0
WORK PACKAGE
TECHNICAL PROCEDURES
BALANCE PISTON ORIFICE PLATE REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-4 ...... 0
Alphabetical Index
Subject Page
Low Pressure Thrust Balance Orifice Plate Installation ............................................................. 3
Low Pressure Thrust Balance Orifice Plate Removal................................................................. 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1714 00
1. Introduction.
This work package contains instructions for removing and installing the low pressure thrust bal-
ance orifice plate. This procedure is designed for engines that have passive Low Pressure Thrust
Balance kit, P/N 682L928, installed.
2. Reference Material.
Title Number
Operations & Maintenance Manual GEK 105059
Engine Operation Chapter 8
Troubleshooting Chapter 10
Illustrated Parts Breakdown GEK 105060
GE Service Bulletin LM6000-IND-0187
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Penetrating Oil GE Spec A50TF54, CL-A
Thread Lubricant GE Spec A50TF201
(MIL-T-5544) or GP460
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Square Seal 9608M08G48 2
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6. Balance Piston Orifice Removal.
A. Apply penetrating oil to nuts and bolts (4, 5, figure 1) that secure orifice plate
between air tube flanges. Remove nuts and bolts and retain for reuse. Remove air
tube, two gaskets, and orifice plate. Discard gaskets.
7. Balance Piston Orifice Installation.
A. Apply thread lubricant to threads of bolts. Install orifice plate and gaskets
(3, 6, figure 1) and secure wiht bolts and nuts (4, 5, figure 1).Torque nuts to
110-120 lb in. (12.4-13.6 N·m).
B. Perform low pressure thrust balance operational check per Chapter 8, Volume I of this
manual. Replace orifice plate if necessary. See Chapter 10, Volume I of this manual
for correct orifice plate
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WP 1714 00
Figure 1. Thrust Balance Orifice Plate, Removal and Installation
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WP 1810 00
0WP 1810 00
WORK PACKAGE
TECHNICAL PROCEDURES
LIQUID FUEL PUMP ASSEMBLY, FUEL FILTER
ASSEMBLY, FUEL PUMP ADAPTER, AND QUICK
DISCONNECT ADAPTER REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1-9 ...... 0
10 Blank . . . . . . 0
Alphabetical Index
Subject Page
Fuel Filter Assembly Installation................................................................................................ 7
Fuel Filter Assembly Removal ................................................................................................... 7
Fuel Pump Adapter Installation .................................................................................................. 9
Fuel Pump Adapter Removal...................................................................................................... 8
Liquid Fuel Pump Assembly Installation.................................................................................... 5
Liquid Fuel Pump Assembly Removal ....................................................................................... 3
Quick Disconnect Adapter Installation ....................................................................................... 6
Quick Disconnect Adapter Removal........................................................................................... 6
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WP 1810 00
1. Introduction.
This work package contains instruction for removing and installing the liquid fuel pump
assembly, quick disconnect adapter, fuel filter assembly, and fuel pump adapter.
(Reference kit, P/N 537L278.)
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Petrolatum Fed Spec VV-P-236
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket 9011M60P01 1
Gasket, Round 9009M74P03 1
Packing, Preformed 140100-110 1
Packing, Preformed J221P904 2
Packing, Preformed J221P906 1
Packing, Preformed J221P916 1
Packing, Preformed J221P224 2
Packing, Preformed J221P216 1
Seal 9057M50P01 1
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WP 1810 00
6. Liquid Fuel Pump Assembly Removal.
See figure 1.
A. Position waste fluid container under fuel pump.
1
WARNING
• Fuel is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
• Fuel system is pressurized. Use care to prevent injury when
disconnecting lines.
CAUTION
Ensure that connecting fitting is restrained when loosening
coupling nut. Failure to comply may result in part damage.
B. Disconnect fuel lines per packager's manual.
C. Loosen machine bolt to disengage from outer ring.
NOTE
Ensure liquid fuel pump assembly is supported while removing outer
ring. Liquid pump assembly weighs approximately 40 lbs (18.1 kg).
D. Using hammer and nylon drift, tap outer ring counterclockwise until outer ring
disengages from pump.
E. Pull fuel pump straight out until drive splines clear gearbox. Remove and discard
preformed packing.
F. Remove and discard seal.
NOTE
If same liquid fuel pump assembly will be installed, disregard step G.
G. Remove fittings from fuel pump ports. Remove and discard preformed packings.
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WP 1810 00
Figure 1. Liquid Fuel Pump Assembly
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WP 1810 00
7. Liquid Fuel Pump Assembly Installation.
See figure 1.
NOTE
If fuel pump fittings are already installed, disregard step A.
A. Install fuel pump fittings as follows (figure 1):
(1) Lubricate new preformed packings using petrolatum.
(2) Install new preformed packing, P/N J221P904, onto pilot pressure union. Install
union into pilot pressure port. Tighten union to 135-150 lb in. (15.3-16.9 N·m) of
torque.
(3) Install new preformed packing, P/N J221P904, onto filter outlet pressure reducer.
Install reducer into filter outlet pressure port. Tighten reducer to 135-150 lb in.
(15.3-16.9 N·m) of torque.
(4) Install new preformed packing, P/N J221P906, onto filter inlet pressure union.
Install union into filter inlet pressure port. Tighten union to 180-220 lb in.
(20.4-24.8 N·m) of torque.
(5) Install new preformed packing, P/N J221P916, onto pump outlet union into pump
outlet port. Tighten union to 700-850 lb in. (79.1-96.0 N·m) of torque.
B. Install new seal, P/N 9057M50P01, onto fuel pump.
C. Lubricate new preformed packing, P/N J221P216, using petrolatum. Install preformed
packing onto fuel pump drive spline.
NOTE
Ensure liquid fuel pump assembly is supported while installing outer
ring. Liquid fuel pump assembly weighs approximately 40 lbs (18.1 kg).
D. Install fuel pump as follows:
(1) Align drive splines and alignment pins. Install fuel pump into quick disconnect
adapter.
(2) Rotate outer ring clockwise to secure fuel pump.
(3) Tighten machine bolt to 190-230 lb in. (21.5-25.9 N·m) of torque.
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WP 1810 00
CAUTION
Ensure that connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
E. Connect fuel lines per packager's manual.
8. Quick Disconnect Adapter Removal.
See figure 2
A. Remove liquid fuel pump assembly per paragraph 6.
B. Remove screws that secure quick disconnect adapter onto gearbox. Remove quick
disconnect adapter.
C. Remove and discard round gasket.
9. Quick Disconnect Adapter Installation.
See figure 2.
A. Install new round gasket, P/N 9009M74P03, onto gearbox.
2 Figure 2. Quick Disconnect Adapter
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WP 1810 00
B. Install quick disconnect adapter onto gearbox ensuring alignment devices are engaged.
Using screws, secure adapter. Tighten screws to 190-230 lb in. (21.5-25.9 N·m) of
torque.
C. Install liquid fuel pump assembly per paragraph 7.
10. Fuel Filter Assembly Removal.
See figure 3.
A. Position waste fluid container under fuel filter assembly.
WARNING
Fuel is flammable and toxic to skin, eyes, and respiratory tract.
Skin and eye protection is required. Avoid repeated or prolonged
contact. Use in a well-ventilated area.
B. Remove drain plug from fuel filter assembly. Allow fuel to drain. Remove and discard
preformed packing.
C. If same fuel filter assembly will be installed, lubricate new packing, P/N 140100-110,
with petrolatum and install onto drain plug.
D. Install drain plug into fuel filter assembly. Tighten drain plug to 135-150 lb in.
(15.3-16.9 N·m) of torque.
E. Remove bolts, nuts, and washers that secure fuel filter assembly to fuel pump.
F. Pull fuel filter assembly away from fuel pump.
G. Remove and discard gasket.
11. Fuel Filter Assembly Installation.
See figure 3.
A. Install new gasket, P/N 9011M60P01, onto fuel filter assembly.
B. Install fuel filter assembly onto fuel pump and secure with washers, nuts, and bolts.
Tighten nuts and bolts to 100-130 lb in. (11.3-14.6 N·m) of torque.
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WP 1810 00
3
Figure 3. Fuel Filter Assembly
12. Fuel Pump Adapter Removal.
See figure 4.
A. Position waste fluid container under fuel pump.
4
WARNING
Fuel is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
B. Remove nuts and washers that secure fuel pump adapter onto fuel pump.
C. Pull fuel pump adapter away from fuel pump.
D. Remove and discard preformed packings.
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WP 1810 00
13. Fuel Pump Adapter Installation.
See figure 4.
A. Lubricate new preformed packings, P/N J221P224, with petrolatum.
B. Install new preformed packings into fuel pump adapter packing grooves.
C. Install fuel pump adapter onto fuel pump and secure with washers and nuts.
D. Tighten nuts to 100-130 lb in. (11.3-14.6 N•m) of torque.
Figure 4. Fuel Pump Adapter
9/(10 Blank)
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WP 1811 00
0WP 1811 00
WORK PACKAGE
TECHNICAL PROCEDURES
HYDRAULIC CONTROL UNIT (HCU) AND HYDRAULIC
FILTER ASSEMBLY REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 10 ...... 0
Alphabetical Index
Subject Page
Hydraulic Control Unit (HCU) Installation ................................................................................ 6
Hydraulic Control Unit (HCU) Removal.................................................................................... 3
Hydraulic Filter Assembly Installation ....................................................................................... 9
Hydraulic Filter Assembly Removal........................................................................................... 9
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1811 00
1. Introduction.
This work package contains instructions for removing and installing the hydraulic control unit
(HCU) and hydraulic filter assembly.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal L28004P01 1
Gasket, Seal L28004P03 1 (ALT)
Gasket, Seal - Fuel Filter 9011M60P01 1
Gasket, Seal J219P03 1
Gasket, Seal J219P04 1
Packing, Preformed J221P910 3
Packing, Preformed J221P908 3
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WP 1811 00
6. Hydraulic Control Unit (HCU) Removal.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
A. Tag and disconnect electrical connectors. See figure 1.
B. Position waste fluid container under HCU.
NOTE
Ensure that lube oil supply is shut off before disconnecting tubing.
C. Disconnect tubing as follows (figure 2):
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(1) Remove bolts and washers that secure variable bypass valve (VBV) head and rod
hoses to HCU. Remove and inspect seal gaskets for serviceability. Discard
damaged seal gasket.
CAUTION
Ensure that connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
(2) Disconnect variable inlet guide vane (VIGV) head and rod tubes from HCU.
(3) Disconnect variable stator vane (VSV) head and rod tubes from HCU.
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WP 1811 00
1
Figure 1. HCU Electrical Connectors
(4) Disconnect thrust balance vane (TBV) head and rod tubes from HCU.
(5) On left side of HCU, disconnect bleed supply and bleed return tubes from HCU.
See figure 3.
NOTE
Ensure HCU is supported while removing nuts and washers. HCU
weighs approximately 75 lbs (34 kg).
D. Remove nuts and washers that secure HCU to variable geometry (VG) hydraulic
pump. Slide HCU off mounting studs. See figure 4.
E. Remove and discard gasket.
NOTE
If same HCU will be installed, disregard step F.
F. Remove all fittings. Remove and discard preformed packings.
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WP 1811 00
2
Figure 2. VBV Hose Locations
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WP 1811 00
3
Figure 3. HCU Bleed Tubes
4
7. Hydraulic Control Unit (HCU) Installation.
NOTE
If HCU fittings are already installed, proceed to step B.
A. Install HCU fittings as follows (figure 2):
WARNING
Lubricating oil, MIL -L-23699, is toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
(1) Lubricate new packings using lubricating oil.
(2) Install new packings, P/N J221P910, onto VIGV, VSV, and TBV head port fit-
tings. Install fittings on HCU. Tighten fittings to 360-400 lb in. (40.7-45.2 N·m) of
torque.
(3) Install new packings, P/N J221P908, onto VIGV, VSV, and TBV rod port fittings.
Install fittings on HCU. Tighten fittings to 270-300 lb in. (30.6-33.9 N·m) of
torque.
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Figure 4. HCU
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B. Install new seal gasket, P/N L28004P01, onto VG hydraulic pump. See figure 4.
NOTE
Ensure HCU is supported while installing washers and nuts. HCU
weighs approximately 75 lbs (34 kg).
C. Install HCU onto VG hydraulic pump and secure with washers and nuts. Tighten nuts
to 100-130 lb in. (11.3-14.6 N·m) of torque.
D. Connect tubing as follows (figure 2):
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
(1) Connect TBV, VSV, and VIGV head tubes onto HCU. Tighten head tube
coupling nuts to 650-770 lb in. (73.5-87.0 N·m) of torque.
(2) Connect TBV, VSV, and VIGV rod tubes onto HCU. Tighten rod tube coupling
nuts to 450-550 lb in. (50.9-62.1 N·m) of torque.
(3) Install new or serviceable seal gasket, P/N J219P03, onto VBV rod-end port.
Using washers and bolts, secure VBV rod hose onto HCU. Tighten bolts to
33-37 lb in.(3.8-4.1 N·m) of torque.
(4) Install seal gasket, P/N J219P04, onto VBV head-end port. Using washers and
bolts, secure VBV head hose onto HCU. Tighten bolts to 33-37 lb in.
(3.8-4.1 N·m) of torque.
(5) Connect bleed supply tube onto HCU. See figure 3. Tighten supply tube coupling
nut to 54-64 lb ft (73.3-86.7 N·m) of torque.
(6) Connect bleed return tube onto HCU. Tighten return tube coupling nut to
79-91 lb ft (107.2-123.3 N·m) of torque.
CAUTION
Ensure electrical connectors are installed at the proper positions.
Failure to comply will cause unreliable engine operation.
E. Connect electrical connectors. See figure 1.
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WP 1811 00
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
8. Hydraulic Filter Assembly Removal.
See figure 5.
A. Position waste fluid container under hydraulic filter assembly.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
B. Remove bolts, nuts, and washers that secure hydraulic filter assembly to HCU. Pull
hydraulic filter assembly away from HCU.
C. Remove and discard gasket.
5
9. Hydraulic Filter Assembly Installation.
See figure 5.
A. Install new gasket, P/N 9011M60P01, onto hydraulic filter assembly.
B. Install hydraulic filter assembly to HCU and secure with bolts, nuts, and washers.
Tighten bolts and nuts to 100-130 lb in. (11.3-14.6 N·m) of torque.
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WP 1811 00
Figure 5. Hydraulic Filter Assembly
10
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WP 1812 00
0Wp 1812 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE GEOMETRY HYDRAULIC PUMP
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
List Of Effective WP Pages
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-4 ...... 1
Alphabetical Index
Subject Page
Variable Geometry Hydraulic Pump Installation ........................................................................ 3
Variable Geometry Hydraulic Pump Removal............................................................................ 3
Change 1 1
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WP 1812 00
1. Introduction.
This work package contains instructions for removing and installing the variable
geometry hydraulic pump.
A. Remove Hydraulic Control Unit (HCU) per WP 1811 00.
B. At the operator's option, the variable geometry hydraulic pump and the HCU may be
removed as a unit. in this case, all steps of WP 1811 00 must be performed, except for
separating the HCU from the pump.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Hydraulic Control Unit (HCU) and WP 1811 00
Hydraulic Filter Assembly Replacement
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Petrolatum Fed Spec VV-P-236
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P260 1
Gasket, Seal J219P04 1
Gasket, Seal J219P05 1
Gasket, Seal J219P07 2
2 Change 1
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6. Variable Geometry Hydraulic Pump Removal.
See figure 1.
A. Position waste fluid container under pump.
1
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
B. Remove nuts and washers that secure oil supply tube onto pump.
C. Remove nuts and washers that secure oil supply tube onto eductor block. Remove tube
and seal gaskets. Inspect gaskets for serviceability. Discard damaged gasket.
D. Remove nuts and washers that secure eductor tube onto pump.
E. Remove nuts and washers that secure eductor tube onto eductor block. Remove tube
and seal gaskets. Inspect gaskets for serviceability. Discard damaged gasket.
F. Remove nuts and washers that secure pump onto gearbox adapter. Remove and dis-
card preformed packing.
7. Variable Geometry Hydraulic Pump Installation.
See figure 1.
A. Lubricate new preformed packing, P/N J221P260, with petrolatum. Install preformed
packing into pump packing groove.
B. Align pump alignment pin with hole in gearbox flange. Engage pump spline in gear-
shaft. Push pump into position against gearbox adapter and secure with washers and
nuts. Tighten nuts evenly, in small increments, in a crisscross pattern to draw pump to
gearbox adapter flange. Tighten nuts to 100-130 lb in. (11.3-14.6 N·m) of torque.
C. Position two new or serviceable oil supply tube seal gaskets, P/N J219P07, one at
pump and one at eductor block. Install oil supply tube and secure with nuts and wash-
ers. Tighten nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
D. Position new or serviceable eductor tube seal gaskets, P/N J219P05 and P/N J219P04,
at pump and eductor block. Install eductor tube and secure with nuts and washers.
Tighten nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
Change 1 3
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WP 1812 00
Figure 1. Variable Geometry Hydraulic Pump
4 Change 1
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1813 00
0WP 1813 00
WORK PACKAGE
TECHNICAL PROCEDURES
LUBE AND SCAVENGE PUMP REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 12
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 11 ...... 1
12 Blank . . . . . . 1
Alphabetical Index
Subject Page
Lube and Scavenge Pump Installation ........................................................................................ 7
Lube and Scavenge Pump Removal............................................................................................ 3
Change 1 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1813 00
1. Introduction.
This work package contains instructions for removing and installing the lube and scavenge
pump.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Magnetic Chip Detector Replacement WP 1910 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P904 2
Packing, Preformed J221P910 1
Gasket, Round 9608M12P04 1
Gasket, Seal 9013M28P02 1
Gasket, Seal 9013M28P01 (ALT)
Gasket, Seal 9013M29P02 1
Gasket, Seal 9013M29P01 (ALT)
Gasket, Seal 9013M30P02 1
Gasket, Seal J219P05 3
Gasket, Seal J219P02 1
Gasket, Seal J219P04 1
Gasket Packager-Supplied 3
2 Change 1
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WP 1813 00
6. Lube and Scavenge Pump Removal.
A. Remove lube and scavenge pump as follows:
(1) Remove electrical cables from clips on electrical bracket.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
(2) Tag and disconnect electrical connectors from chip detectors and resistance
temperature detector (RTD)s. See figure 2.
1
(3) Position waste fluid container under lube and scavenge pump.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
NOTE
Ensure lube oil supply is shut off before disconnecting tubing.
(4) Disconnect tubes and hoses from lube and scavenge pump and oil manifolds.
NOTE
Ensure lube and scavenge pump is supported when removing V-band
clamp. Lube and scavenge pump weighs approximately 25 lbs
(11.3 kg).
(5) Remove V-band clamp that secures lube and scavenge pump. See figure 2. Pull
pump straight out until drive spline clears gearbox. Remove round gasket and
inspect for serviceability. Discard damaged gasket.
2
Change 1 3
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WP 1813 00
Figure 1. Lube and Scavenge Pump and Oil Manifold Ports (Sheet 1 of 2)
4 Change 1
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WP 1813 00
Figure 1. Lube and Scavenge Pump and Oil Manifold Ports (Sheet 2 of 2)
Change 1 5
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Fiigure 2. Lube and Scavenge Pump
6 Change 1
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WP 1813 00
NOTE
If same lube and scavenge pump will be installed, disregard steps B.,
C., and D.
B. Remove oil manifolds as follows (figure 3):
3
(1) Remove bolts (1 and 9) and washers (2 and 10) that secure oil supply
manifold (3), oil lube and scavenge manifold (11), and scavenge oil
manifold (14) onto lube and scavenge pump (20). Remove manifolds.
(2) Disconnect coupling nut on air/oil separator tube (5). Remove air/oil separator
fitting (8). Remove and discard preformed packing (7).
(3) Remove bolts (4) that secure air/oil separator tube (5) onto lube and scavenge
pump (20) lube and scavenge. Remove air/oil separator tube.
(4) Remove bolts (16) and washers (17) that secure E-sump scavenge oil
manifold (18) onto lube and scavenge pump (20). Remove manifold.
(5) Remove gaskets (6, 12, 13, 15, and 19) and inspect for serviceability. Discard
damaged gaskets.
C. Remove spline lube and seal drain fittings. Remove and discard packings.
D. Remove chip detectors from lube and scavenge pump per WP 1910 00.
7. Lube and Scavenge Pump Installation.
NOTE
If chip detectors, spline lube and seal drain fittings, and oil
manifolds are installed, disregard steps A., B., and C.
A. Install chip detectors into lube and scavenge pump per WP 1910 00.
B. Install fittings as follows (figure 2):
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(1) Lubricate new preformed packings, P/N J221P904, with lubricating oil. Install
preformed packings onto spline lube and seal drain fittings.
Change 1 7
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WP 1813 00
Figure 3. Typical Oil Manifolds
8 Change 1
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WP 1813 00
(2) Install spline lube and seal drain fittings into spline lube and seal drain ports.
Tighten fittings to 135-150 lb in. (15.3-16.9 N·m) of torque.
C. Install oil manifolds as follows (figure 3):
(1) Install new or serviceable gaskets, P/N 9013M29P02 (12), P/N 9013M28P02
(13), and P/N 9013M30P02 (15), onto lube and scavenge pump (20).
(2) Position oil supply manifold (3), oil lube and scavenge manifold (11), and
scavenge oil manifold (14) onto lube and scavenge pump (20) and secure with
washers (2 and 10) and bolts (1 and 9). Tighten bolts to 55-70 lb in. (6.3-7.9 N·m)
of torque.
(3) Install new or serviceable gasket, P/N J219P04 (19), onto rear of lube and
scavenge pump (20). Install E-sump scavenge oil manifold (18) and secure with
washers (17) and bolts (16). Tighten bolts to 33-37 lb in. (3.8-4.1 N·m) of torque.
(4) Install new gasket, P/N J219P02 (6), onto air/oil separator tube (5). Connect
air/oil separator tube (5) onto lube and scavenge pump (20) and secure with bolts
(4). Tighten bolts to 33-37 lb in. (3.8-4.1 N·m) of torque.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(5) Lubricate new preformed packing (7), P/N J221P910, with lubricating oil. Install
preformed packing onto air/oil separator fitting (8).
CAUTION
Ensure connecting fitting is restrained when tightening cou-
pling nut. Failure to comply may result in part damage.
(6) Connect air/oil separator tube (5) to air/oil separator fitting (8). Tighten coupling
nut to 650-770 lb in. (73.5-87.0 N·m) of torque.
D. Install lube and scavenge pump as follows :
(1) Install round gasket, P/N 9608M12P04, onto lube and scavenge pump. Align hole
in gasket with antitorque pin on pump.
(2) Position lube and scavenge pump in front of gearbox, aligning drive shaft splines
and antitorque pin. Slide pump into gearbox until housing seats.
Change 1 9
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WP 1813 00
NOTE
Ensure lube and scavenge pump is supported while installing V-band
clamp. Lube and scavenge pump weighs approximately 25 lbs
(11.3 kg).
(3) Secure lube and scavenge pump onto gearbox using V-band clamp. Tighten clamp
to 70-90 lb in. (8.0-10.1 N·m) of torque.
E. Connect oil tubes and hoses as follows (figure 2):
(1) Install packager-supplied gasket. Connect oil tube onto lube supply outlet (L3)
port and secure with bolts. Tighten bolts to 325-425 lb in. (36.8-48.0 N·m) of
torque.
(2) Install packager-supplied gasket. Connect oil tube onto lube supply inlet (L1) port
and secure with bolts. Tighten bolts to 500-700 lb in. (56.5-79.1 N·m) of torque.
(3) Install packager-supplied gasket. Connect oil tube onto scavenge discharge (L2)
port and secure with bolts. Tighten bolts to 425-550 lb in. (48.1-62.1 N·m) of
torque.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
(4) Connect lube oil tube onto lube discharge port fitting. Tighten coupling nut to
900-1090 lb in. (101.7-123.1 N·m) of torque.
(5) Connect oil tube onto supply pressure (L4) port fitting. Tighten coupling nut to
270-300 lb in. (30.6-33.9 N·m) of torque.
(6) Connect scavenge tube onto scavenge discharge pressure (L5) port fitting. Tighten
coupling nut to 270-300 lb in. (30.6-33.9 N·m) of torque.
(7) Connect oil manifold tube onto gearbox oil supply port fitting. Tighten coupling
nut to 270-300 lb in. (30.6-33.9 N·m) of torque.
(8) Connect oil tube onto compressor rear frame (CRF) oil supply port fitting.
Tighten coupling nut to 450-550 lb in. (50.9-62.1 N·m) of torque.
(9) Connect oil tube onto turbine rear frame (TRF) oil supply port fitting. Tighten
coupling nut to 900-1090 lb in. (101.7-123.1 N·m) of torque.
(10) Connect accessory gearbox scavenge tube/hose onto accessory gearbox (AGB)
scavenge in port fitting. Tighten coupling nut to 650-770 lb in. (73.5-87.0 N·m)
of torque.
10 Change 1
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(11) Connect D-sump lube scavenge tube onto D-sump scavenge in port fitting.
Tighten coupling nut to 650-770 lb in. (73.5-87.0 N·m) of torque.
(12) Connect E-sump lube scavenge tube onto E-sump scavenge in port fitting.
Tighten coupling nut to 650-770 lb in. (73.5-87.0 N·m) of torque.
(13) Install new gasket, P/N J219P05, onto transfer gearbox scavenge tube. Connect
tube onto transfer gearbox scavenge in port and secure with bolts. Tighten bolts
to 55-70 lb in. (6.3-7.9 N·m) of torque.
(14) Install new gasket, P/N J219P05, onto B-sump scavenge tube. Connect tube onto
B-sump scavenge in port and secure with bolts. Tighten bolts to 55-70 lb in.
(6.3-7.9 N·m) of torque.
(15) Install new gasket, P/N J219P05, onto C-sump scavenge tube. Install tube onto
C sump scavenge in port and secure with bolts. Tighten bolts to 55-70 lb in.
(6.3-7.9 N·m) of torque.
(16) Connect oil tube onto spline lube port fitting. Tighten coupling nut to
135-150 lb in. (15.3-16.9 N·m) of torque.
(17) Connect hose assembly onto seal drain port fitting. Tighten coupling nut to
135-150 lb in. (15.3-16.9 N·m) of torque.
F. Connect electrical connectors to RTDs and chip detectors as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
G. Install electrical cables into clips on electrical bracket.
Change 1 11/(12 Blank)
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WP 1814 00
0WP 1814 00
WORK PACKAGE
TECHNICAL PROCEDURES
PNEUMATIC STARTER REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-7 ...... 0
8 Blank ...... 0
Alphabetical Index
Subject Page
Pneumatic Starter Installation ..................................................................................................... 6
Pneumatic Starter Removal......................................................................................................... 3
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1814 00
1. Introduction.
A. This work package contains instructions for removing and installing the pneumatic starter.
(Reference kit, P/N 682L184.)
B. Prior to operation, service new pneumatic starter per WP 4022 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Pneumatic Starter Servicing WP 4022 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket 9107M23P01 1
Gasket L22281P02 1
Packing, Preformed J221P904 1
Packing, Preformed J221P906 1
Packing, Preformed J221P908 1
Packing, Preformed J221P222 1
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WP 1814 00
6. Pneumatic Starter Removal.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
A. Tag and disconnect electrical connector from pneumatic starter. See figure 1.
1
CAUTION
Ensure air supply is shut off before disconnecting air/gas inlet
hose. Failure to comply may result in part damage.
B. Remove V-band clamp that secures air/gas inlet hose onto pneumatic starter. Remove
and discard gasket.
C. Disconnect air/gas outlet hose from pneumatic starter per packager's manual.
D. Position waste fluid container under pneumatic starter.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply can result in part damage.
E. Disconnect tubes and hoses from pneumatic starter fittings.
2
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WP 1814 00
Figure 1. Pneumatic Starter
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Figure 2. Pneumatic Starter Fittings
NOTE
Ensure pneumatic starter is supported when removing nuts. Pneumatic
starter weighs approximately 50 lbs (22.7 kg).
F. Remove nuts that secure pneumatic starter to transfer gearbox (TGB). Reposition oil
scavenge tube bracket. Remove pneumatic starter.
G. Remove and discard gasket.
H. Remove and discard preformed packings from starter drive shaft.
NOTE
If same pneumatic starter will be installed, proceed to paragraph 7.
I. Remove fittings and discard packings. See figure 2.
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7. Pneumatic Starter Installation.
A. If a new pneumatic starter is installed, service starter per WP 4022 00.
NOTE
If fittings are already installed, proceed to step C.
B. Install fittings as follows (figure 2):
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated
or prolonged contact. Use in well-ventilated area.
(1) Lubricate all new preformed packings using lubricating oil.
(2) Install new preformed packing, P/N J221P906, onto reducer. Install reducer into
air supply port.
(3) Install new preformed packing, P/N J221P904, onto elbow. Install elbow into oil
scavenge port. Tighten jamnut finger-tight.
(4) Install new preformed packing, P/N J221P908, onto union. Install union into oil
scavenge port. Tighten union to 270-300 lb in. (30.5-33.9 N·m) of torque.
C. Install new preformed packing, P/N J221P222, onto pneumatic starter drive shaft.
See figure 1.
D. Install new gasket, P/N 9107M23P01, onto TGB starter adapter.
NOTE
Ensure pneumatic starter is supported when installing nuts. Pneumatic
starter weighs approximately 50 lbs (22.7 kg).
E. Align pneumatic starter so maintenance drain plug is at 6:00 o'clock position and
install onto TGB. Install oil scavenge tube bracket onto TGB studs. Secure starter and
bracket using nuts. Tighten nuts to 190-230 lb in. (21.5-25.9 N·m) of torque.
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WP 1814 00
F. Connect tubes and hoses as follows:
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
(1) Connect tube/hose onto air supply reducer. Tighten coupling nut to 450-550 lb in.
(50.9-62.1 N·m) of torque.
(2) Align oil in elbow with oil tube. Tighten jamnut on elbow to 135-150 lb in.
(15.3-16.9 N·m) of torque. Connect oil tube onto oil in elbow. Tighten coupling
nut to 135-150 lb in. (15.3-16.9 N·m) of torque.
(3) Connect oil scavenge tube to oil scavenge union. Tighten coupling nut to
450-550 lb in. (50.9-62.1 N·m) of torque.
(4) Install new gasket, P/N L22281P02, on air/gas inlet hose. Using V-band clamp,
secure air/gas inlet hose to pneumatic starter. Tighten V-band clamp to
90-100 lb in. (10.2-11.3 N·m) of torque.
(5) Install air/gas outlet hose onto pneumatic starter per packager's manual.
G. Connect electrical connector to pneumatic starter as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
7/(8 Blank)
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 1815 00
8WP 1815 00
WORK PACKAGE
TECHNICAL PROCEDURES
HYDRAULIC STARTER AND DISTRIBUTOR
ASSEMBLY REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 2
Alphabetical Index
Subject Page
Distributor Assembly Installation ............................................................................................... 7
Distributor Assembly Removal................................................................................................... 6
Hydraulic Starter Installation ...................................................................................................... 4
Hydraulic Starter Removal.......................................................................................................... 3
Hydraulic Starter Spline Lubrication .......................................................................................... 4
Seal Drain and Cooling Interface Installation............................................................................. 8
Seal Drain and Cooling Interface Removal ................................................................................ 8
Change 2 1
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1815 00
1. Introduction.
This work package contains instructions for removing and installing hydraulic starter and
distributor assembly. (Reference kit, P/N 537L379G05.)
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Hammer, Soft-faced Local Purchase
4. Consumable Material.
Nomenclature Specification
Grease, Molybdenum Disulfide MIL-G-21164
Isopropyl Alcohol Fed Spec TT-I-735
Lubricating Oil MIL-L-23699
5. Expendable Material.
Reference GEK 105060 , Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket 9107M23P01 1
Packing, Preformed J221P222 1
Packing, Preformed J221P912 1
Packing, Preformed J221P904 1
Packing, Preformed J221P219 2
2 Change 2
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WP 1815 00
6. Hydraulic Starter Removal.
See figure 1.
WARNING
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Skin
and eye protection is required. Avoid repeated or prolonged con-
tact. Use in a well-ventilated area.
A. Position waste fluid container under hydraulic starter.
WARNING
Pressure of 100 psig exists in the supply lines. Relieve pressure to
prevent injury when disconnecting fittings.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
B. Disconnect hydraulic lines per packager's manual.
1
Figure 1. Hydraulic Starter
Change 2 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1815 00
NOTE
Ensure hydraulic starter is supported when removing nuts. Hydraulic
starter weighs approximately 100 pounds (45.4 kg).
C. Remove nuts that secure hydraulic starter to gearbox. Remove hydraulic starter.
D. Remove and discard preformed packing from starter drive shaft.
E. Remove and discard gasket.
6A.Hydraulic Starter Spline Lubrication.
See figure 1A.
A. Remove shaft retainer from drive shaft by prying out carefully from groove with
screwdriver.
B. Remove drive shaft from starter.
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
C. Using Isopropyl alcohol and clean cloth, clean drive shaft and shaft cavities to remove
old lubricant.
D. Apply grease, MIL-G-21164, liberally by hand to cover splines of drive shaft.
E. Reinstall drive shaft in starter.
F. Reinstall shaft retainer by tapping into drive shaft cavity with soft-faced hammer.
Retainer will snap into groove when properly installed.
7. Hydraulic Starter Installation.
See figure 1.
A. Install new preformed packing, P/N J221P222, onto starter drive shaft.
B. Install new gasket, P/N 9107M23P01, onto gearbox starter adapter.
4 Change 2
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WP 1815 00
NOTE
Ensure hydraulic starter is supported when installing nuts. Hydraulic
starter weighs approximately 100 pounds (45.4 kg).
C. Align hydraulic starter so cooling supply interface is at 12:00 o'clock position. Using
nuts, install hydraulic starter onto gearbox starter adapter. Tighten nuts to
190-230 lb in. (21.5-25.9 N·m) of torque.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
D. Connect hydraulic lines per packager's manual.
Figure 1A. Hydraulic Starter Spline Lubrication (Sheet 1 of 2)
Change 2 5
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WP 1815 00
2
1
Figure 1A. Hydraulic Starter Spline Lubrication (Sheet 2 of 2)
8. Distributor Assembly Removal.
See figure 2.
WARNING
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Skin
and eye protection is required. Avoid repeated or prolonged con-
tact. Use in a well-ventilated area.
A. Position waste fluid container under hydraulic starter.
B. Disconnect hydraulic line to distributor assembly per packager's manual.
C. Remove bolts that secure distributor assembly to starter. Remove distributor
assembly. Discard preformed packing.
6 Change 2
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WP 1815 00
1
Figure 2. Distributor Assembly
9. Distributor Assembly Installation.
See figure 2.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in well-ventilated area.
A. Lubricate new preformed packing, P/N J221P219, using lubricating oil. Install
packing onto distributor assembly.
B. Using bolts, install distributor assembly onto starter. Tighten bolts to 250-320 lb in.
(28.3-36.1 N·m) of torque.
C. Connect hydraulic line to distributor assembly per packager's manual.
Change 2 7
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WP 1815 00
10. Seal Drain and Cooling Interface Removal.
See figure 1.
A. Remove fittings from case drain and seal drain ports. Discard preformed packings.
11. Seal Drain and Cooling Interface Installation.
See figure 1.
A. Install fittings as follows:
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in well-ventilated area.
(1) Lubricate all new preformed packings using lubricating oil.
(2) Install new preformed packing, P/N J221P904, onto union. Install union into seal
drain port. Tighten union to 135-150 lb in. (15.3-16.9 N·m) of torque.
(3) Install new preformed packing, P/N J221P912, onto union. Install union into case
drain port. Tighten union to 540-600 lb in. (61.1-67.8 N·m) of torque.
8 Change 2
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1816 00
0WP 1816 00
WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR SPEED (XN25)
SENSOR REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-6 ...... 1
Alphabetical Index
Subject Page
High Pressure Compressor Speed (XN25) Sensor Installation................................................... 3
High Pressure Compressor Speed (XN25) Sensor Removal ...................................................... 3
Change 1 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1816 00
1. Introduction.
This work package contains instructions for removing and installing the high pressure
compressor speed (XN25) sensor.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Silicone Rubber Adhesive GE Spec A15F6B6
(RTV 106)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket J219P04 1
2 Change 1
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WP 1816 00
6. High Pressure Compressor Speed (XN25) Sensor Removal.
See figure 1.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure that location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
NOTE
There are two identical XN25 sensors on left side of gearbox.
A. Tag and disconnect electrical connector from XN25 sensor.
B. Loosen jamnut and remove XN25 sensor from gearbox port. Remove and retain
jamnut.
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
CAUTION
Use care to ensure old silicone rubber adhesive does not fall
into gearbox. Failure to comply may cause part damage.
C. Using isopropyl alcohol, clean old silicone rubber adhesive from gearbox.
1
7. High Pressure Compressor Speed (XN25) Sensor Installation.
See figure 1.
A. Remove bolts that secure gearbox access cover or AGB vent tube(s). Remove access
cover or move AGB vent tube(s) out of the way, and remove gasket. Inspect gasket for
serviceability. Discard damaged gasket.
B. Install jamnut onto XN25 sensor.
Change 1 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1816 00
Figure 1. High Pressure Compressor Speed (XN25) Sensor
4 Change 1
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WP 1816 00
C. Install and adjust XN25 sensor to meet required gap of 0.010-0.015 in.
(0.25-0.38 mm) between sensor tip and tooth crown of gear. Using feeler gage inserted
through gearbox opening, check for required gap. GAP:
WARNING
Vapor from uncured sealant is flammable and toxic to skin, eyes,
and respiratory tract. Avoid contact with skin and eyes. Use in a
well-ventilated area.
D. Apply a thin bead of silicone rubber adhesive around XN25 sensor at gearbox.
Diameter of bead shall be approximately 0.06 inch (1.5 mm).
NOTE
Tighten jamnut while silicone rubber adhesive is still wet.
E. Hold XN25 sensor and tighten jamnut to 90-110 lb in. (10.2-12.4 N·m) of torque.
F. Using feeler gage, recheck gap between sensor tip and tooth crown of gear. Gap shall
be between 0.010-0.015 in. (0.25-0.38 mm). Safety-wire jamnut. GAP:
NOTE
Package vent system may have been installed as part of the
package installation. Refer to the packager´s information for
proper installation.
G. Install new or serviceable gasket, P/N J219P04, and cover or connect vent tube(s) with
gasket, P/N MS27196-16 onto gearbox access opening, and secure using bolts.
Tighten bolts to 33-37 lb in. (3.8-4.1 N·m) of torque. Safety-wire bolts.
H. Connect electrical connector to XN25 sensor as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
Change 1 5
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WP 1816 00
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
(5) Safety-wire electrical connector.
6 Change 1
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WP 1817 00
0WP 1817 00
WORK PACKAGE
TECHNICAL PROCEDURES
LUBE RESISTANCE TEMPERATURE DETECTOR
(RTD) REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 0
6 Blank ...... 0
Alphabetical Index
Subject Page
Lube Resistance Temperature Detector Installation ................................................................... 3
Lube Resistance Temperature Detector Removal ....................................................................... 3
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1817 00
1. Introduction.
This work package contains instructions for removing and installing lube resistance temperature
detector (RTD).
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
5. Expendable Material.
Reference GEK 105060 , Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P904 1
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1817 00
6. Lube Resistance Temperature Detector Removal.
See figure 1.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure that location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
A. Tag and disconnect electrical connector from RTD.
B. Position waste fluid container under lube and scavenge pump.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
C. Remove RTD from lube and scavenge pump manifold or boss on transfer gearbox
(TGB) scavenge tube. Remove and discard preformed packing.
1
7. Lube Resistance Temperature Detector Installation.
See figure 1.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
A. Lubricate new preformed packing, P/N J221P904, with lubricating oil and install into
RTD packing groove.
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WP 1817 00
Figure 1. Lube Resistance Temperature Detector (RTD)
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WP 1817 00
CAUTION
Use care to prevent damage to RTD tip.
B. Install RTD into lube and scavenge pump manifold or boss on TGB scavenge tube.
Tighten RTD to 135-150 lb in. (15.3-16.9 N·m) of torque.
C. Connect electrical connector to RTD as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
5/(6 Blank)
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WP 1910 00
0WP 1910 00
WORK PACKAGE
TECHNICAL PROCEDURES
MAGNETIC CHIP DETECTOR REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 0
6 Blank ...... 0
Alphabetical Index
Subject Page
Magnetic Chip Detector Installation ........................................................................................... 3
Magnetic Chip Detector Removal............................................................................................... 3
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 1910 00
1. Introduction.
This work package contains instructions for removal and installation of the magnetic chip
detector.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P905 1
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WP 1910 00
6. Magnetic Chip Detector Removal.
See figure 1.
A. Position waste fluid container under lube and scavenge pump.
1
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
B. Tag and disconnect electrical connector from chip detector.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
C. Remove chip detector from lube and scavenge pump or oil manifold block. Remove
and discard preformed packing.
7. Magnetic Chip Detector Installation.
See figure 1.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
A. Lubricate new preformed packing, P/N J221P905, with lubricating oil. Install new
preformed packing onto chip detector.
B. Install chip detector into lube and scavenge pump or oil manifold block. Tighten chip
detector to 155-175 lb in. (17.6-19.7 N·m) of torque.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1910 00
Figure 1. Magnetic Chip Detector
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WP 1910 00
C. Safety-wire chip detector.
D. Connect electrical connector to chip detector as follows:
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
5/(6 Blank)
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WP 1911 00
5WP 1911 00
WORK PACKAGE
TECHNICAL PROCEDURES
ACCELEROMETER REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-7 ...... 0
8 Blank ...... 0
Alphabetical Index
Subject Page
Compressor Rear Frame Accelerometer Installation .................................................................. 3
Compressor Rear Frame Accelerometer Removal...................................................................... 3
Turbine Rear Frame Accelerometer Installation......................................................................... 7
Turbine Rear Frame Accelerometer Removal ............................................................................ 5
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1911 00
1. Introduction.
This work package contains instructions for removing and installing the compressor rear frame
(CRF) and turbine rear frame (TRF) accelerometers.
2. Reference Material.
None required.
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
None required.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1911 00
6. Compressor Rear Frame Accelerometer Removal.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
A. Remove bolts that secure CRF accelerometer integral lead loop clamps onto brackets.
Remove clamps from CRF accelerometer integral lead.
B. Remove nut and bolt that secure CRF accelerometer integral lead loop clamp onto
bracket. Remove clamp from CRF accelerometer integral lead.
C. Tag and disconnect electrical connector from CRF accelerometer integral lead. See
figure 1.
1
D. Remove jamnut that secures CRF accelerometer integral lead onto No. 3 electrical
interface panel.
E. Remove bolts that secure CRF accelerometer onto bracket. Remove CRF
accelerometer.
7. Compressor Rear Frame Accelerometer Installation.
A. Install CRF accelerometer onto bracket. See figure 1.
B. Using bolts, secure CRF accelerometer onto bracket. Tighten bolts to 55-70 lb in.
(6.3-7.9 N·m) of torque.
C. Secure CRF accelerometer integral lead onto No. 3 electrical interface panel with
jamnut. Tighten jamnut to 25-35 lb in. (2.8-4.0 N·m) of torque and safety-wire.
D. Connect electrical connector to CRF accelerometer integral lead as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1911 00
Figure 1. CRF Accelerometer
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WP 1911 00
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed connector pliers. Tighten connector 1/4-1/2 turn, or until plier
slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3) as required. It may be necessary to loosen lead
clamps that restrict mating.
E. Install loop clamps onto integral lead.
F. Using bolt and nut, secure loop clamp onto bracket. Tighten nut to 55-70 lb in.
(6.2-7.9 N·m) of torque.
G. Using bolts, secure loop clamps onto brackets. Tighten bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
8. Turbine Rear Frame Accelerometer Removal.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installa-
tion. Failure to comply may cause unreliable engine operation.
A. Remove bolts that secure TRF accelerometer integral lead loop clamps onto brackets.
Remove clamps from TRF accelerometer integral lead (section W-W).
B. Tag and disconnect electrical connector from TRF accelerometer integral lead.
See figure 2.
C. Remove jamnut that secures TRF accelerometer integral lead onto No. 4 electrical
interface panel.
2
D. Remove bolts that secure TRF accelerometer onto bracket. Reposition XNSD lead
clamp bracket. Remove TRF accelerometer (view X).
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WP 1911 00
Figure 2. TRF Accelerometer
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WP 1911 00
9. Turbine Rear Frame Accelerometer Installation.
A. Install TRF accelerometer onto bracket. Position XNSD lead clamp bracket on
accelerometer. See figure 2.
B. Using bolts, secure TRF accelerometer onto bracket. Tighten bolts to 55-70 lb in.
(6.3-7.9 N·m) of torque and safety-wire.
C. Using jamnut, secure TRF accelerometer integral lead onto No. 4 electrical interface
panel. Tighten jamnut to 25-35 lb in. (2.8-4.0 N·m) of torque and safety-wire.
D. Connect electrical connector to TRF accelerometer integral lead.
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed connector pliers. Torque connector 1/4-1/2 turn, or until plier
slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) (4)Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
E. Install loop clamps onto TRF accelerometer integral lead.
F. Using bolts, secure clamps onto brackets. Tighten bolts to 55-70 lb in. (6.3-7.9 N·m)
of torque.
7/(8 Blank)
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 1912 00
0WP 1912 00
WORK PACKAGE
TECHNICAL PROCEDURES
LIQUID FUEL MANIFOLD TEMPERATURE SENSOR
REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 0
6 Blank ...... 0
Alphabetical Index
Subject Page
Liquid Fuel Manifold Temperature Sensor Installation .............................................................. 3
Liquid Fuel Manifold Temperature Sensor Removal ................................................................. 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1912 00
1. Introduction.
This work package contains instructions for removing and installing primary or secondary liquid
fuel manifold temperature sensor.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
None required.
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Seal 9371M19P04 1
Seal 9371M19P104 (ALT)
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WP 1912 00
6. Liquid Fuel Manifold Temperature Sensor Removal.
A. Position waste fluid container under fuel manifold.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure that location of electrical connector is noted to aid at installation.
Failure to comply may cause unreliable engine operation.
B. Disconnect electrical connector from fuel manifold temperature sensor (figure 1).
1
WARNING
• Fuel system is pressurized. Use care to prevent injury when
disconnecting lines.
• Fuel is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
C. Remove fuel manifold temperature sensor. Remove and discard seal.
D. If required, remove second fuel manifold temperature sensor per steps B. and C.
7. Liquid Fuel Manifold Temperature Sensor Installation.
A. Install new seal, P/N 9371M19P04, onto fuel manifold temperature sensor (figure 1).
B. Install sensor into primary or secondary fuel temperature sensor port. Tighten sensor
to 135-150 lb in. (15.3-16.9 N·m) of torque.
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WP 1912 00
Figure 1. Liquid Fuel Manifold Temperature Sensor
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WP 1912 00
C. Connect electrical connector to sensor.
WARNING
Electrical power shall be off before connecting or discon-
necting electrical connectors. Electricity causes shock,
burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling backshell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed connector pliers. Torque connector 1/4-1/2 turn, or until plier
slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
D. If removed, install second fuel manifold temperature sensor per steps A, B, and C.
5/(6 Blank)
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WP 1913 00
0WP 1913 00
WORK PACKAGE
TECHNICAL PROCEDURES
EXTERNAL PIPING, HOSES, AND ELECTRICAL
HARNESS REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 2
Page Change Page Change Page Change
No. No. No. No. No. No.
1-2 ...... 0
Alphabetical Index
Subject Page
Arrangement................................................................................................................................ 2
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WP 1913 00
1. Introduction.
This work package introduces the external configuration work packages. For specific work
instructions, refer to the following: SWP 1913 01
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Front Frame Module External Tubing, Harnesses, and SWP 1913 01
Clamping
Core Module External Tubing, Electrical Leads, and
Clamping SWP 1913 02
Low Pressure Turbine (LPT) Module External Tubing,
Harnesses, and Clamping SWP 1913 03
Engine Assembly External Tubing, Harnesses, and Clamping SWP 1913 04
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Reference SWP 1913 01, SWP 1913 02, SWP 1913 03, and SWP 1913 04 for a list of
consumable material.
5. Expendable Material.
Due to the variety of gaskets, packings, seals, etc. used during installation of external
tubing, expendable materials are not listed. Refer to Illustrated Parts Breakdown (IPB),
GEK 105060 , for required parts.
6. Arrangement.
A. SWP 1913 01 contains information for installation of front frame module external
tubing, harnesses, and clamping.
B. SWP 1913 02 contains information for installation of core module external tubing,
harnesses, and clamping.
C. SWP 1913 03 contains information for installation of engine assembly external tubing,
harnesses, and clamping.
D. SWP 1913 04 contains information for final installation of engine assembly external
tubing, harnesses, and clamping.
2
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SWP 1913 01
3SWP 1913 01
SUBORDINATE WORK PACKAGE
TECHNICAL PROCEDURES
FRONT FRAME MODULE EXTERNAL TUBING,
HARNESSES, AND CLAMPING
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 42
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 42 ...... 5
Alphabetical Index
Subject Page
Air Collector Brackets Installation ............................................................................................. 4
Front Frame Module Brackets Installation ................................................................................. 4
Front Frame Module Electrical Cables Installation .................................................................... 4
Front Frame Module Tubing and Clamping Installation ............................................................ 4
Transfer Gearbox Assembly Brackets Installation ..................................................................... 4
Transfer Gearbox Assembly Tubing and Clamping Installation ................................................ 4
Change 5 1
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Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
1. Introduction.
A. This subordinate work package contains information concerning installation of front
frame module external tubing, harnesses, and clamping.
B. The following general instructions shall be met any time tubing, electrical leads,
harnesses, or cables are disturbed:
(1) Unless otherwise specified, bend radii for an electrical lead, cable, or harness must
exhibit a smooth transition. No kinks allowed.
(2) Electrical connections of heads and harnesses shall conform to the following
assembly points:
(a) Engage connector with its mating interface and turn knurled coupling ring,
while wiggling backshell assembly.
(b) After fully seating connector by hand, apply final torque to coupling ring
using Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier
slippage occurs.
(c) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(d) Repeat substeps (b) and (c), as required. It may be necessary to loosen lead
clamps that restrict mating.
(3) Torque all remaining nuts of mis-alignment fittings as follows:
Tube Size OD Torque
(inches) (mm) (lb ft) (N·m)
0.75-1.0 (19.0-25.4) 24-26 (32.5-35.2)
1.125-1.50 (28.57-38.1) 20-40 (27.1-54.2)
1.625-2.0 (41.27-50.8) 40-50 (54.2-67.8)
2.125 and up (53.9 and up) 50-60 (67.8-81.3)
(4) Unless otherwise noted, install all bolts with boltheads forward.
2 Change 5
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SWP 1913 01
(5) If any external tube or manifold does not fit in the free state at assembly within
0.060 inch (1.52 mm) and is known to be within manufacturing tolerance, it shall
be modified by bending as required. After bending, to obtain the required f
ree-state fit, the following shall apply:
(a) Part shall conform to original specification and pressure requirements.
(b) Bend radii shall not be less than manufacturing limits.
(c) Coupling nuts shall thread freely by hand.
(d) End flange fittings shall seat flush within 0.005 inch (0.12 mm).
(e) End points of tube or manifold shall align with mating connector with
0.060 inch (1.52 mm) in all planes.
(f) A minimum clearance of 0.125 inch (3.17 mm) shall be maintained between
tube OD and adjacent parts.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-PRF-23699F (C/I)
Molybdenum Disulfide Lubricant MIL-L-25681
Safety Cable 736L680G01
Safety Wire (0.020 inch) R297P02
Safety Wire (0.032 inch) R297P04 (ALT)
Silicone Tape MIL-I-46852
Thread Lubricant GE Spec A50TF201
Zinc Chromate Primer Fed Spec TT-P-1757
5. Expendable Material.
Due to the variety of gaskets, packings, seals, etc. used during installation of external
tubing, expendable materials are not listed. Refer to Illustrated Parts Breakdown (IPB),
GEK 105060, for required parts.
Change 5 3
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SWP 1913 01
6. Air Collector Brackets Installation.
See figure 1 and table 1.
1
7. Transfer Gearbox Assembly Brackets Installation.
See figure 2 and table 2.
2
8. Transfer Gearbox Assembly Tubing and Clamping Installation.
See figure 3 and table 3.
3
9. Front Frame Module Brackets Installation.
See figure 4 and table 4.
4
10. Front Frame Module Tubing and Clamping Installation.
See figure 5 and table 5.
5
11. Front Frame Module Electrical Cables Installation.
See figure 6 and table 6.
7
6
4 Change 5
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SWP 1913 01
Figure 1. Air Collector Brackets (Sheet 1 of 2)
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SWP 1913 01
Figure 1. Air Collector Brackets (Sheet 2 of 2)
6 Change 5
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SWP 1913 01
Table 1. Air Collector Brackets (See figure 1.)
Attach To Secure
Item Item With Torque Notes
VSV/VBV bracket Air collector/front Bolts (2) 55-70 lb in. (a) (b) (e)
(1) frame aft flange (6.3-7.9 N·m)
VSV/VBV bracket Air collector/front Bolts (2) 55-70 lb in. (a) (b) (e)
(3) frame aft flange (6.3-7.9 N·m)
Electrical bracket Air collector/front Bolts (2) 55-70 lb in. (a) (b) (e)
(4) frame aft flange (6.3-7.9 N·m)
VSV/VBV bracket Air collector/front Bolts (2), 55-70 lb in. (b) (f) (g)
(1) frame aft flange Spacer (18) (6.3-7.9 N·m)
Electrical bracket Air collector/front Bolts (2), 55-70 lb in. (b) (f) (g)
(4) frame aft flange Spacer (18) (6.3-7.9 N·m)
VSV/VBV bracket Air collector/front Bolts (2), 55-70 lb in. (b) (f) (g)
(3) frame aft flange Spacer (18) (6.3-7.9 N·m)
Electrical bracket Aft lower right Bolts (6), 480-570 lb in. (a) (c)
(5) flange Nuts (7) (54.3-64.4 N·m)
Panel bracket (8) Forward lower Bolts (6), 480-570 lb in. (a) (c)
right flange Nuts (7) (54.3-64.4 N·m)
Panel bracket (9) Air collector/front Bolts (10), 55-70 lb in. (a) (d)
frame forward Nuts (11) (6.3-7.9 N·m)
flange
Electrical Aft lower left Bolts (6), 480-570 lb in. (a) (c)
bracket (12) flange Nuts (7) (54.3-64.4 N·m)
Electrical Aft lower left Bolts (6), 480-570 lb in. (a) (c)
bracket (13) flange Nuts (7) (54.3-64.4 N·m)
VSV/VBV Air collector aft Bolts (15) 55-70 lb in.
Bracket (14) face (6.3-7.9 N·m)
VSV/VBV Air collector right Bolts (15), 55-70 lb in.
Bracket (16) side Washers (17) (6.3-7.9 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using molybdenum disulfide lubricant.
(b) Safety-wire with safety cable, 736L680.
(c) Boltheads face outboard.
(d) Boltheads face aft.
(e) Before Service Bulletin LM6000-IND-0258.
(f) After Service Bulletin LM6000-IND-0258.
(g) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
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Figure 2. Transfer Gearbox Assembly Brackets (Sheet 1 of 2)
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Figure 2. Transfer Gearbox Assembly Brackets (Sheet 2 of 2)
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Table 2. Transfer Gearbox Assembly Brackets (See figure 2.)
Attach To Secure
Item Item With Torque Notes
Mounting bracket Gearbox housing Bolts (2), 190-230 lb in. (a)
(1) Washers (3), Nuts (21.5-25.9 N·m)
(4)
Electrical bracket Gearbox housing Washers (6), Nuts 55-70 lb in.
(5) (7) (6.2-7.9 N·m)
Mounting bracket Gearbox housing Bolts (10) 190-230 lb in. (a) (b)
(8) and Tubing (21.5-25.9 N·m)
bracket (9)
Electrical Bevel gear housing Washers (12), 190-230 lb in. (b)
bracket (11) Bolts (13) (21.5-25.9 N·m)
Electrical Bevel gear housing Washers (12), 55-70 lb in. (b)
bracket (14) Bolts (25) (6.2-7.9 N·m)
Oil bracket (15) VG hydraulic pump Bolts (16) 55-70 lb in. (b)
adapter (6.2-7.9 N·m)
Lube bracket (17) VG hydraulic pump Bolts (16) 55-70 lb in. (b) (c)
adapter (6.2-7.9 N·m)
Lube bracket (18) Gearbox housing Bolts (19) 33-37 lb in.
(3.7-4.2 N·m)
Lube bracket (18) Gearbox housing Bolts (20), 300-360 lb in.
Washers (21), (33.9-40.6 N·m)
Nuts (22)
Electrical Manual drive Washers (6), 55-70 lb in. (b)
bracket (23) adapter assembly Bolts (16) (6.2-7.9 N·m)
Electrical Manual drive Washers (6), 55-70 lb in. (b)
bracket (24) adapter assembly Bolts (16) (6.2-7.9 N·m)
Mounting bracket Gearbox housing Bolts (10) 190-230 lb in. (a) (b)
(8) (21.5-25.9 N·m)
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SWP 1913 01
Table 2. Transfer Gearbox Assembly Brackets (See figure 2.) (Continued)
Attach To Secure
Item Item With Torque Notes
Manifold bracket Gearbox housing Bolts (27) 190-230 lb in.
(26) (21.5-25.9 N·m)
WARNING
Zinc Chromate Primer, TT-P-1757, is highly toxic to skin,
eyes, and respiratory tract. Skin and eye protection, and vapor
control are required. Avoid all contact.
NOTES:
(a) Coat mating surfaces of bracket and gearbox housing using zinc chromate primer.
(b) Safety-wire.
(c) Nut plates face aft.
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Figure 3. Transfer Gearbox Assembly Tubing and Clamping (Sheet 1 of 3)
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Figure 3. Transfer Gearbox Assembly Tubing and Clamping (Sheet 2 of 3)
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Figure 3. Transfer Gearbox Assembly Tubing and Clamping (Sheet 3 of 3)
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Table 3. Transfer Gearbox Assembly Tubing and Clamping (See figure 3.)
Attach To Secure
Item Item With Torque Notes
Electrical bracket Oil supply Bolts (2) 55-70 lb in.
(1) manifold (6.2-7.9 N·m)
Preformed Oil manifold 180-200 lb in. (a)
packing (3), (20.4-22.6 N·m)
Union (4)
Preformed Oil supply 135-155 lb in. (a)
packing (5), Plug manifold (15.3-17.5 N·m)
(6)
Preformed Oil supply 180-200 lb in. (a)
packing (7), manifold (20.4-22.6 N·m)
Union (8)
Preformed Lube and scavenge 135-155 lb in. (a)
packing (9), manifold (15.3-17.5 N·m)
Plug (10)
Preformed Lube and scavenge 360-400 lb in.
packing (11), manifold (40.6-45.2 N·m)
Union (12)
Gasket (13), Oil scavenge Bolts (15) 55-70 lb in.
Oil tube (14) manifold (6.2-7.9 N·m)
Preformed Oil supply 360-400 lb in. (a)
packing (16), manifold (40.6-45.2 N·m)
Union (17)
Gasket (18), Gearbox housing Bolts (21) 33-37 lb in.
AGB tube/hose (3.7-4.2 N·m)
(19), Oil drain
bracket (20)
AGB tube/hose Union (17) Coupling nut 650-770 lb in.
(19) (73.4-87.0 N·m)
AGB tube/hose Manual drive Clamp (22), Bolt 33-37 lb in.
(19) adapter (23) (3.7-4.2 N·m)
Preformed AGB tube/hose 135-155 lb in. (a) (b)
packing (24), (19) (15.3-17.5 N·m)
Plug (25)
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Table 3. Transfer Gearbox Assembly Tubing and Clamping (See figure 3.) (Continued)
Attach To Secure
Item Item With Torque Notes
Preformed Fuel pump adapter 135-155 lb in. (a)
packing (26), (15.3-17.5 N·m)
Union (27)
Preformed Gearbox housing 135-155 lb in. (a)
packing (28), fuel pump pad (15.3-17.5 N·m)
Union (29)
Hose assembly Union (29) Coupling nut 135-155 lb in.
(30) (15.3-17.5 N·m)
Preformed Gearbox housing Coupling nut 135-155 lb in. (a)
packing (31), starter pad (15.3-17.5 N·m)
Oil drain tube (32)
Oil manifold (33) Union (27), Coupling nuts 135-155 lb in.
Hose assembly (15.3-17.5 N·m)
(30), Oil drain tube
(32)
Oil manifold (33) Manifold bracket Clamp (34), Bolt 33-37 lb in.
(26, figure 2) (35), Nut (36) (3.7-4.2 N·m)
Oil manifold (33) Oil drain bracket Clamp (37), Bolt 33-37 lb in.
(20) (35), Nut (36) (3.7-4.2 N·m)
Preformed Lube and scavenge 135-155 lb in. (a)
packing (38), pump (15.3-17.5 N·m)
Union (39)
Hose assembly Oil manifold (33), Coupling nuts 135-155 lb in.
(40) Union (39) (15.3-17.5 N·m)
Hose assembly Electrical bracket Clamp (41), 55-70 lb in.
(40) (23, figure 2) Bolts (42) (6.2-7.9 N·m)
Hose assembly AGB tube/hose Clamps (43, 44), 33-37 lb in.
(40) (19) Bolts (35), Nuts (3.7-4.2 N·m)
(36)
Preformed Lube and scavenge 135-155 lb in. (a)
packing (45), pump (15.3-17.5 N·m)
Union (46)
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Table 3. Transfer Gearbox Assembly Tubing and Clamping (See figure 3.) (Continued)
Attach To Secure
Item Item With Torque Notes
Preformed Oil manifold 360-400 lb in. (a)
packing (47), (40.6-45.2 N·m)
Union (48)
Preformed AGB tube/hose 135-155 lb in. (a)
packing (49), (19) (15.3-17.5 N·m)
RTD sensor (50)
Preformed Oil supply 540-600 lb in. (a)
packing (51), manifold (61.1-67.8 N·m)
Union (52)
Preformed Oil supply 270-300 lb in. (a)
packing (53), manifold (30.6-33.9 N·m)
Union (54)
Preformed Oil manifold 135-155 lb in. (a)
packing (55), (15.3-17.5 N·m)
Plug (56)
Preformed Oil manifold 135-155 lb in. (a)
packing (57), (15.3-17.5 N·m)
Plug (58)
Preformed Oil manifold 360-400 lb in. (a)
packing (59), (40.6-45.2 N·m)
Union (60)
Gasket (61), Lube and scavenge Bolts (63) 33-37 lb in. (a)
Air/Oil separator pump (3.7-4.2 N·m)
tube (62)
Air/Oil separator Union (60) Coupling nut 650-770 lb in.
tube (62) (73.4-87.0 N·m)
Preformed Oil manifold 540-600 lb in. (a)
packing (64), (61.1-67.8 N·m)
Union (65)
Preformed Oil manifold 540-600 lb in. (a)
packing (66), (61.1-67.8 N·m)
Oil tube (67)
Change 5 17
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Table 3. Transfer Gearbox Assembly Tubing and Clamping (See figure 3.) (Continued)
Attach To Secure
Item Item With Torque Notes
Oil tube (68) Oil tube (67), Coupling nut 75-91 lb ft
Union (65) (102-123 N·m)
Preformed Oil manifold 135-155 lb in. (a)
packing (69), (15.3-17.5 N·m)
Plug (70)
Preformed Oil manifold 180-200 lb in. (a)
packing (71), (20.4-22.6 N·m)
Union (72)
Oil manifold (73) Union (72) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Oil manifold (73) Tubing bracket Clamp (37), 55-70 lb in.
(9, figure 2) Bolts (42) (6.2-7.9 N·m)
Gasket (74), VG hydraulic pump Washers (76), 33-37 lb in.
Lube tube (75) Nuts (36) (3.7-4.2 N·m)
Gasket (77), Oil manifold Bolts (42) 55-70 lb in.
Lube tube (75) (6.2-7.9 N·m)
Lube tube (75) Lube bracket Clamp (41), 55-70 lb in.
(18, figure 2) Bolts (42) (6.2-7.9 N·m)
Gasket (78), VG hydraulic pump Washers (80), 55-70 lb in.
Lube tube (79) Nuts (81) (6.2-7.9 N·m)
Gasket (82), Oil manifold Bolts (42) 55-70 lb in.
Lube tube (79) (6.2-7.9 N·m)
Preformed HCU, TBV Head 360-400 lb in. (a)
packing (83), (40.7-45.2 N·m)
Union (84)
Preformed HCU, TBV Rod 270-300 lb in. (a)
packing (85), (30.6-33.9 N·m)
Union (86)
Preformed HCU, VSV and 360-400 lb in. (a)
packing (87), VIGV Head (40.7-45.2 N·m)
Union (88)
18 Change 5
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Table 3. Transfer Gearbox Assembly Tubing and Clamping (See figure 3.) (Continued)
Attach To Secure
Item Item With Torque Notes
Gasket (91), Oil tube (14) Bolts (93), Nuts 55-70 lb in. (a)
Oil tube (92) (94) (6.2-7.9 N·m)
Gasket (95), Transfer gearbox Bolts (35) 55-70 lb in.
Oil tube (92) housing (6.2-7.9 N·m)
Preformed HCU, VSV and 270-300 lb in.
packing (89), VIGV Rod (30.6-33.9 N·m)
Union (90)
Oil tube (92) Lube bracket Clamp (96), 55-70 lb in.
(17, figure 2) Bolt (42) (6.2-7.9 N·m)
Oil tube (92) Oil bracket Clamp (96), 55-70 lb in.
(15, figure 2) Bolt (42), (6.2-7.9 N·m)
Washer (97), Nut
(94)
Oil tube (98) Oil manifold (73) Coupling nut 135-155 lb in.
(15.3-17.5 N·m)
Oil tube (98) Union (46) Coupling nut 135-155 lb in.
(15.3-17.5 N·m)
Oil tube (98) Lube bracket Clamp (34), 33-37 lb in.
(18, figure 2) Bolt (99), Washer (3.7-4.2 N·m)
(100), Nut (36)
Cap assembly Oil tube (98) 135-155 lb in.
(101) (15.3-17.5 N·m)
Preformed Accessory gearbox 155-175 lb in. (a)
packing (102), housing (17.6-19.7 N·m)
Reducer (103)
Oil manifold (104) Reducer (103) Coupling nut 180-200 lb in.
(20.4-22.6 N·m)
Oil manifold (104) Oil manifold (73) Coupling nut 180-200 lb in.
(20.4-22.6 N·m)
Oil manifold (104) Accessory gearbox Clamp (105), 55-70 lb in.
housing Bolt (106) (6.2-7.9 N·m)
Change 5 19
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Table 3. Transfer Gearbox Assembly Tubing and Clamping (See figure 3.) (Continued)
Attach To Secure
Item Item With Torque Notes
Preformed Transfer gearbox 155-175 lb in. (a)
packing (107), housing (17.6-19.8 N·m)
Reducer (108)
Oil tube (109) Reducer (108) Coupling nut 135-155 lb in.
(15.3-17.5 N·m)
Oil tube (109) Oil manifold (104) Coupling nut 135-155 lb in.
(15.3-17.5 N·m)
Preformed VG hydraulic pump 180-200 lb in.
packing (71), (20.4-22.6 N·m)
Plug (110)
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Per-
sonal protective equipment required. Use mechanical exhaust
ventilation - if not available, use an approved respirator.
NOTES:
(a) Lubricate preformed packing using lubricating oil.
(b) Safety-wire.
20 Change 5
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Figure 4. Front Frame Module Brackets
Change 5 21
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Table 4. Front Frame Module Brackets (See figure 4.)
Attach To Secure
Item Item With Torque Notes
Mount pad (1) Front frame Bolts (2) 480-570 lb in. (a)
(54.3-64.4 N·m)
VBV bracket (3) Front frame Washers (4), Bolts 55-70 lb in.
(5) (6.2-7.9 N·m)
VSV/VBV bracket Front frame Washers (4), Bolts 55-70 lb in.
(6) (5) (6.2-7.9 N·m)
Electrical bracket Transfer gearbox Washers (4), Bolts 55-70 lb in. (b)
(7) mount plate (8) (6.2-7.9 N·m)
Electrical bracket Transfer gearbox Washers (4), Bolts 55-70 lb in. (b)
(9) mount plate (8) (6.2-7.9 N·m)
Electrical Transfer gearbox Washers (4), Bolts 55-70 lb in. (b)
bracket (10) mount plate (8) (6.2-7.9 N·m)
Oil bracket (11) Electrical Bolts (5) 55-70 lb in.
bracket (10) (6.2-7.9 N·m)
No. 2 electrical Electrical brackets Bolts (13) 55-70 lb in.
interface panel (12) (9, 10) (6.2-7.9 N·m)
No. 2 electrical Transfer gearbox Washers (4), 190-230 lb in.
interface panel (12) mount bracket Bolts (14) (21.5-25.9 N·m)
VSV/VBV Front frame Washers (4), Bolts 55-70 lb in.
bracket (15) (5) (6.2-7.9 N·m)
VSV/VBV Front frame Washers (4), Bolts 55-70 lb in.
bracket (16) (5) (6.2-7.9 N·m)
Electrical Front frame Bolts (18) 55-70 lb in.
bracket (17) (6.2-7.9 N·m)
NOTES:
(a) Coat threads of bolts with molybdenum disulfide lubricant.
(b) Safety-wire.
22 Change 5
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Figure 5. Front Frame Module Tubing and Clamping (Sheet 1 of 5)
Change 5 23
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Figure 5. Front Frame Module Tubing and Clamping (Sheet 2 of 5)
24 Change 5
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Figure 5. Front Frame Module Tubing and Clamping (Sheet 3 of 5)
Change 5 25
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Figure 5. Front Frame Module Tubing and Clamping (Sheet 4 of 5)
26 Change 5
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Figure 5. Front Frame Module Tubing and Clamping (Sheet 5 of 5)
Change 5 27
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Table 5. Front Frame Module Tubing and Clamping (See figure 5.)
Attach To Secure
Item Item With Torque Notes
Gasket (1), HCU Bolts (3), 33-37 lb in.
Oil tube/hose (2) Washers (4) (3.7-4.2 N·m)
(Initial
configuration)
Gasket (5), HCU Bolts (3), 33-37 lb in.
VBV oil hose (6) Washers (4) (3.7-4.2 N·m)
(Initial
configuration)
Teflon hose (7) Union Coupling nut 650-770 lb in.
(Initial (88, figure 3) (73.4-87.0 N·m)
configuration)
Oil tube/hose (8) Union Coupling nut 450-550 lb in.
(Initial (90, figure 3) (50.8-62.1 N·m)
configuration)
VBV oil tube (9) Oil tube/hose (2) Coupling nut 75-91 lb ft
(Initial (102-123 N·m)
configuration)
VSV oil tube (10) Oil tube/hose (8) Coupling nut 450-550 lb in.
(Initial (50.8-62.1 N·m)
configuration)
VSV oil tube (11) Teflon hose (7) Coupling nut 650-770 lb in.
(Initial (73.4-87.0 N·m)
configuration)
VBV oil tube (12) VBV oil hose (6) Coupling nut 112-128 lb ft
(Initial (151.9-173.5 N·m)
configuration)
VBV oil tubes (9, VSV/VBV bracket, Clamps (13, 14), 55-70 lb in.
12), VSV oil tubes (16, figure 1) Bolts (15), (6.2-7.9 N·m)
(10, 11) (Initial Washers (16), and
configuration) Nuts (17)
VBV oil tubes (9, VSV/VBV bracket, Clamps (18, 19), 55-70 lb in.
12), VSV oil tubes (14, figure 1) Bolts (15), (6.2-7.9 N·m)
(10, 11) (Initial Washers (16), and
configuration) Nuts (17)
28 Change 5
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Table 5. Front Frame Module Tubing and Clamping (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
Gasket (20), Front frame Bolts (22) 55-70 lb in. (a)
Air elbow (21) (6.2-7.9 N·m)
Oil manifold (23) VSV/VBV bracket, Clamp (24), 55-70 lb in.
(16, figure 4) Bolt (22), (6.2-7.9 N·m)
Washer (25), and
Nut (17)
Oil manifold (23) VSV/VBV bracket, Clamp (24), 55-70 lb in.
(15, figure 4) Bolt (22), (6.2-7.9 N·m)
Washer (25), and
Nut (17)
Oil manifold (26) VSV/VBV bracket, Clamp (24), 55-70 lb in.
(16, figure 4) Bolt (22), (6.2-7.9 N·m)
Washer (25), Nut
(17)
Oil manifold (26) VSV/VBV bracket Clamp (24), Bolt 55-70 lb in.
(15, figure 4) (22), Washer (25), (6.2-7.9 N·m)
Nut (17)
Preformed VBV actuator rod 135-155 lb in. (b)
packing (27), end port (6 places) (15.3-17.5 N·m)
Reducer (28)
VBV oil tube (29) Oil manifold (26) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
VBV oil tube (29) Reducer (28) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Preformed VBV actuator head 135-155 lb in. (b)
packing (30), end port (6 places) (15.3-17.5 N·m)
Reducer (31)
Preformed Oil tube (35) (b)
packings (32, 33),
Drain can (34)
Oil tube (35) Oil manifold (23) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Change 5 29
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Table 5. Front Frame Module Tubing and Clamping (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
Oil tube (35) Reducer (31) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Drain can (34) VBV actuator head Hand-tight (c)
end port
Oil drain tube (36) Drain can (34) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Oil manifold (37) Oil manifold (26) Coupling nut 650-770 lb in.
(73.4-87.0 N·m)
Oil manifold (37) Reducer (28) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Preformed Oil tube (35) (b)
packings (32, 33),
Drain can (34)
Oil manifold (38) Oil manifold (23) Coupling nut 650-770 lb in.
(73.4-87.0 N·m)
Oil manifold (38) Reducer (31) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Drain can (34) VBV actuator head Hand-tight (c)
end port
Oil drain tube (39) Drain can (34) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Oil drain tube (39) Oil drain tube (36) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Oil manifolds (37, VSV/VBV bracket Clamp (40), Bolt 55-70 lb in.
38) Oil drain tube (3, figure 1) (41), Washer (25), (6.2-7.9 N·m)
(39) Nut (17)
Oil drain tube (39) VSV/VBV bracket Clamp (42), Bolt 55-70 lb in.
(15, figure 4) (22), Washer (25), (6.2-7.9 N·m)
Nut (17)
Oil manifold (43) VSV/VBV bracket Clamp (44), Bolt 55-70 lb in.
(6, figure 4) (22), Washer (25), (6.2-7.9 N·m)
Nut (17)
30 Change 5
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Table 5. Front Frame Module Tubing and Clamping (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
Oil manifold (43) VBV bracket Clamp (24), Bolt 55-70 lb in.
(3, figure 4) (22), Washer (25), (6.2-7.9 N·m)
Nut (17)
Oil manifold (45) VSV/VBV bracket Clamp (24), Bolt 55-70 lb in.
(6, figure 4) (22), Washer (25), (6.2-7.9 N·m)
Nut (17)
Oil manifold (45) VBV bracket Clamp (24), Bolt 55-70 lb in.
(3, figure 4) (22), Washer (25), (6.2-7.9 N·m)
Nut (17)
VBV oil tube (46) Oil manifold (43) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
VBV oil tube (46) Reducer (28) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Preformed Oil tube (47) (b)
packings (32, 33),
Drain can (34)
Oil tube (47) Oil manifold (45) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Oil tube (47) Reducer (31) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Drain can (34) VBV actuator head Hand-tight (c)
end port
Oil drain tube (48) Drain can (34) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Oil manifold (49) Oil manifold (43) Coupling nut 650-770 lb in.
(73.4-87.0 N·m)
Oil manifold (49) Reducer (28) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Preformed Oil tube (50) (b)
packings (32, 33),
Drain can (34)
Change 5 31
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Table 5. Front Frame Module Tubing and Clamping (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
Oil tube (50) Oil manifold (45) Coupling nut 650-770 lb in.
(73.4-87.0 N·m)
Oil tube (50) Reducer (31) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Drain can (34) VBV actuator head Hand-tight (c)
end port
Oil drain tube (51) Drain can (34) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Oil drain tube (51) Oil drain tube (48) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Oil manifold (49), VSV/VBV bracket Clamp (40), Bolt 55-70 lb in.
Oil tube (50), (1, figure 1) (41), Washer (25), (6.2-7.9 N·m)
Oil drain tube (51) Nut (17)
Oil drain tube (51) VBV bracket Clamp (42), Bolt 55-70 lb in.
(3, figure 4) (22), Washer (25), (6.2-7.9 N·m)
Nut (17)
Preformed Oil tube (52) (b)
packings (32, 33),
Drain can (34)
Oil tube (52) Reducer (31) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Drain can (34) VBV actuator head Coupling nut Hand-tight (c)
end port
Oil tube (53) Reducer (28) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Oil tube (54) Reducer (28) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
Preformed Oil tube (55) (b)
packings (32, 33),
Drain can (34)
Oil tube (55) Reducer (31) Coupling nut 270-300 lb in.
(30.6-33.9 N·m)
32 Change 5
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Table 5. Front Frame Module Tubing and Clamping (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
Drain can (34) VBV actuator head Hand-tight (c)
end port
VSV teflon Union Coupling nut 650-770 lb in.
hose (56) (88, figure 4) (73.4-86.9 N·m)
VBV teflon HCU Bolts (60) 33-37 lb in.
hose (57) Washers (61) (3.7-4.2 N·m)
Gasket (62)
VBV teflon HCU Bolts (60) 33-37 lb in.
hose (58) Washers (61) (3.7-4.2 N·m)
Gasket (63)
Reducer (64)
VSV teflon Union Coupling nut 450-550 lb in.
hose (59) (90, figure 4) (50.8-62.1 N·m)
VSV teflon Together Clamps (65, 66, 57) 55-70 lb in.
hose (56, 59) Bolt (70) (6.2-7.9 N·m)
VBV teflon Nut (71)
hose (57, 58)
VSV teflon VSV/VBV bracket Clamps (65, 66, 57) 55-70 lb in.
hose (56, 59) (68) (16, figure 1) Bolt (70) (6.2-7.9 N·m)
VBV teflon Nut (71)
hose (57, 58)
VSV/VBV Front frame Bolts (69) 55-70 lb in.
bracket (6.2-7.9 N·m)
NOTES:
(a) Safety-wire.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Per-
sonal protective equipment required. Use mechanical exhaust
ventilation - if not available, use an approved respirator.
(b) Lubricate packings using lubricating oil.
(c) Align drain fittings before tightening.
Change 5 33
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Figure 6. Front Frame Module Electrical Cables (Sheet 1 of 4)
34 Change 5
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Figure 6. Front Frame Module Electrical Cables (Sheet 2 of 4)
Change 5 35
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Figure 6. Front Frame Module Electrical Cables (Sheet 3 of 4)
36 Change 5
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Figure 6. Front Frame Module Electrical Cables (Sheet 4 of 4)
Change 5 37
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 01
Table 6. Front Frame Module Electrical Cables (See figure 1.)
Attach To Secure
Item Item With Torque Notes
Preformed T25 sensor 90-100 lb in. (a) (b)
packing (19), (10.2-11.3 N·m)
Plug (20)
T25 sensor/Integral Air collector upper Bolt (21) 33-37 lb in. (b)
lead (1) left (3.7-4.2 N·m)
T25 sensor/Integral VSV/VBV bracket Clamp (9), Bolt 55-70 lb in. (a)
lead (1) (3, figure 1) (11) (6.2-7.9 N·m)
Electrical bracket Clamp (9), Bolt 55-70 lb in. (a)
(4, figure 1) (11) (6.2-7.9 N·m)
Electrical bracket Clamps (14), 55-70 lb in. (a)
(17, figure 4) Bolts (11) (6.2-7.9 N·m)
Electrical bracket Spring clip (a)
(7, figure 4)
No. 2 electrical Jamnut Hand-tight, then (c)
interface panel 1/4 to 1/2 turn
(12, figure 4)
CAUTION
Routing of harness is completed during final engine assembly.
Ensure loose connector is secured to avoid damage during trans-
port.
Left side VBV actuator Connector ring Hand-tight
VSV/VBV/LVDT (11:00 o'clock)
electrical cable (2)
VSV/VBV bracket Clamp (14), Bolt 55-70 lb in. (a)
(3, figure 1) (11) (6.2-7.9 N·m)
Electrical bracket Clamp (14), Bolt 55-70 lb in. (a)
(4, figure 1) (11) (6.2-7.9 N·m)
Electrical bracket Clamps (14), 55-70 lb in. (a)
(17, figure 4) Bolts (11) (6.2-7.9 N·m)
Electrical bracket Clamps (13), 55-70 lb in. (a)
(7, figure 4) Bolt (11) (6.2-7.9 N·m)
38 Change 5
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 01
Table 6. Front Frame Module Electrical Cables (See figure 1.) (Continued)
Attach To Secure
Item Item With Torque Notes
No. 2 electrical Jamnut Hand-tight, then (c)
interface panel 1/4 to 1/2 turn
(12, figure 4)
Gas generator XN25 sensor Connector ring Hand-tight (c)
speed electrical
cable (3)
Electrical bracket Spring clip (a)
(7, figure 4)
No. 2 electrical Jamnut Hand-tight, then (c)
interface panel 1/4 to 1/2 turn
(12, figure 4)
Gas generator XN25 sensor Connector ring Hand-tight (b)
speed electrical
cable (4)
Electrical bracket Spring clip (a)
(12, figure 1)
No. 2 electrical Jamnut Hand-tight, then (c)
interface panel 1/4 to 1/2 turn
(12, figure 4)
T25 sensor/integral Electrical bracket Clamps (9, 10, 13) 55-70 lb in. (c)
lead (1), left side (13, figure 1) Bolt (11), Nut (12) (6.2-7.9 N·m)
VBV/VSV LVDT
electrical cable (2),
Gas generator
speed electrical
cable (4)
Chip detector Common scavenge Connector ring Hand-tight
electrical cable (5) chip detector
Tubing bracket Spring clip (a)
(9, figure 2)
Lube bracket Spring clip (a)
(17, figure 2) (2 places)
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Table 6. Front Frame Module Electrical Cables (See figure 1.) (Continued)
Attach To Secure
Item Item With Torque Notes
B-sump scavenge Connector ring Hand-tight
chip detector
TGB/A-sump Connector ring Hand-tight
scavenge chip
detector
Electrical bracket Spring clips (a)
(23, figure 2)
Electrical bracket Spring clip (a)
(14, figure 2)
Chip detector Electrical bracket Spring clip (a)
electrical cable (5) (5, figure 2)
Electrical bracket Spring clip (a)
(7, figure 4)
No. 2 electrical Jamnut Hand-tight, then (c)
interface panel 1/4 to 1/2 turn
(12, figure 4)
TGB/A, AGB, B, AGB scavenge Connector ring Hand-tight
C lube RTD RTD
electrical cable (6)
Electrical bracket Clamp (15), Bolt 55-70 lb in. (a)
(24, figure 2) (11) (6.2-7.9 N·m)
TGB/A sump Connector ring Hand-tight
scavenge RTD
B-sump scavenge Connector ring Hand-tight
RTD
C-sump scavenge Connector ring Hand-tight
RTD
Electrical bracket Clamp (17), Bolt 55-70 lb in. (a)
(11, figure 2) (11) (6.2-7.9 N·m)
Electrical bracket Clamp (17), Bolt 55-70 lb in. (a)
(7, figure 4) (11) (6.2-7.9 N·m)
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Table 6. Front Frame Module Electrical Cables (See figure 1.) (Continued)
Attach To Secure
Item Item With Torque Notes
No. 2 electrical Jamnut Hand-tight, then (b)
interface panel 1/4 to 1/2 turn
(12, figure 4)
D, E, supply lube D, E-sump Connector ring Hand-tight
RTD electrical scavenge, supply
cable (7) RTD
D-sump branch of D-sump scavenge Connector ring Hand-tight
electrical cable (7) RTD
Electrical bracket Clamp (16), Bolt 55-70 lb in. (a)
(7, figure 4) (11) (6.2-7.9 N·m)
Electrical bracket Clamp (16), Bolt 55-70 lb in. (a)
(5, figure 1) (11), Nut (12) (6.2-7.9 N·m)
Oil bracket Clamp (16), Bolt 55-70 lb in. (a)
(15, figure 2) (11) (6.2-7.9 N·m)
E-sump & supply Oil bracket Clamp (18), Bolt 55-70 lb in. (a)
branch of electrical (11, figure 4) (11) (6.2-7.9 N·m)
cable (7)
E-sump branch of Oil bracket Clamp (16), Bolt 55-70 lb in. (a)
electrical cable (7) (11, figure 4) (11) (6.2-7.9 N·m)
Electrical bracket Clamp (16), Bolt 55-70 lb in. (a)
(1, figure 3) (11) (6.2-7.9 N·m)
Main cable No. 2 electrical Jamnut Hand-tight, then (c)
interface panel 1/4 to 1/2 turn
(12, figure 4)
CAUTION
Routing of harness is completed during final engine assembly.
Ensure loose connector is secured to avoid damage during trans-
port.
Right side VBV actuator (5:00 Connector ring Hand-tight
VBV/VSV LVDT o'clock position)
electrical cable (8)
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Table 6. Front Frame Module Electrical Cables (See figure 1.) (Continued)
Attach To Secure
Item Item With Torque Notes
Electrical bracket Clamp (14), Bolt 55-70 lb in. (a)
(7, figure 4) (11) (6.2-7.9 N·m)
No. 2 electrical Jamnut Hand-tight, then (c)
interface panel 1/4 to 1/2 turn
(12, figure 4)
NOTES:
(a) Lead may be spiral wrapped using silicone tape in the area of spring clips or clamps and 0.50
inch (12.7 mm) on either side of clip or clamp to provide positive lead clamping as required.
(b) Safety-wire using R297P02 safety wire.
(c) Safety-wire to adjacent jamnut using R297P02 safety wire.
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3SWP 1913 02
SUBORDINATE WORK PACKAGE
TECHNICAL PROCEDURES
CORE MODULE EXTERNAL TUBING, ELECTRICAL
LEADS, AND CLAMPING
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 48
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 48 ...... 4
Alphabetical Index
Subject Page
Core Module Brackets Installation ............................................................................................. 4
Core Module Tubing and Clamping Installation ........................................................................ 4
CRF Accelerometer Integral Lead Installation ........................................................................... 4
CRF Aft Case to CRF Brackets Installation ............................................................................... 4
CRF/HPT Flange Brackets Installation....................................................................................... 4
HPC/CRF Flange Brackets Installation ...................................................................................... 4
HPT Tubing Installation .............................................................................................................. 4
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1. Introduction.
A. This subordinate work package contains information concerning installation of core module
external tubing, harnesses, and clamping, including high pressure compressor (HPC), compres-
sor rear frame (CRF), and high pressure turbine (HPT).
B. The following general instructions shall be met any time tubing, electrical leads, harnesses, or
cables are disturbed:
(1) Unless otherwise specified, the bend radii for an electrical lead, cable, or harness must
exhibit a smooth transition. No kinks allowed.
(2) Electrical connections of heads and harnesses shall conform to the following assembly
points:
(a) Engage the connector with its mating interface and turn knurled coupling ring, while
wiggling the backshell assembly.
(b) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed connector pliers. Torque connector 1/4-1/2 turn, or until plier slippage
occurs.
(c) Check for full seating by wiggling accessory assembly. There shall be no movement
with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(d) Repeat substeps (b) and (c), as required. It may be necessary to loosen lead clamps that
restrict mating.
(3) Torque all remaining nuts of misalignment fittings as follows:
Tube Size OD Torque
(inches) (mm) (lb ft) (N·m)
0.75-1.00 (19.1-25.4) 24-26 (32.5-35.2)
1.125-1.50 (28.58-38.1) 20-40 (27.1-54.2)
1.625-2.00 (41.28-50.8) 40-50 (54.2-67.8)
2.125 and up (54.0 and up) 50-60 (67.8-81.3)
(4) Unless otherwise noted, install all bolts with boltheads forward.
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(5) If any external tube or manifold does not fit in the free state at assembly within 0.060 inch
(1.52 mm) and is known to be within manufacturing tolerance, it shall be modified by
bending, as required. After bending, to obtain the required free-state fit, the following shall
apply:
(a) Part shall conform to original specification and pressure requirements.
(b) Bend radii shall not be less than manufacturing limits.
(c) Coupling nuts shall thread freely by hand.
(d) End flange fittings shall seat flush within 0.005 inch (0.13 mm).
(e) End points of tube or manifold shall align with mating connector with 0.060 inch
(1.52 mm) in all planes.
(f) (f)A minimum clearance of 0.125 inch (3.18 mm) shall be maintained between tube
OD and adjacent parts.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Engine Assembly External Tubing, Harnesses, and Clamping SWP 1913 04
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.020 inch) R297P02
Safety Wire (0.032 inch) R297P04 (ALT)
Silicone Tape MIL-I-46852
Thread Lubricant GP460
5. Expendable Material.
Due to the variety of gaskets, packings, seals, etc., used during installation of external tubing,
expendable materials are not listed. Refer to Illustrated Parts Breakdown, GEK105060, for
required parts.
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6. HPC/CRF Flange Brackets Installation.
See figure 1 and table 1.
1
7. CRF/HPT Flange Brackets Installation.
See figure 2 and table 2.
2
8. CRF Aft Case to CRF Brackets Installation.
See figure 3 and table 3.
3
9. Core Module Brackets Installation.
See figure 4 and table 4.
4
10. HPT Tubing Installation.
See figure 5 and table 5 for original configuration. See figure 5A and table 5A for current
configuration.
6
5
11. Core Module Tubing and Clamping Installation.
See figure 6 and table 6.
7
12. CRF Accelerometer Integral Lead Installation.
See figure 7 and table 7.
8
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Figure 1. HPC/CRF Flange Brackets (Sheet 1 of 3)
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Figure 1. HPC/CRF Flange Brackets (Sheet 2 of 3)
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Figure 1. HPC/CRF Flange Brackets (Sheet 3 of 3)
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Table 1. HPC/CRF Flange Brackets (See figure 1.)
Attach To Secure
Item Item With Torque Notes
Air/Oil bracket (1) Bolthole 9, 11 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
(43.0-47.4 N·m)
Cooling bracket (4) Bolthole 18, 21 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
(43.0-47.4 N·m)
Air Cooling bracket Bolthole 30, 32 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
(5) (43.0-47.4 N·m)
Air/Oil bracket (6) Bolthole 33, 35 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
(43.0-47.4 N·m)
Air/Oil bracket (7) Bolthole 39, 41 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
(43.0-47.4 N·m)
Air/Oil bracket (8) Bolthole 42, 44 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
(43.0-47.4 N·m)
Accelerometer Bolthole 45, 47 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
bracket (9) (43.0-47.4 N·m)
Accelerometer Bolthole 51, 53 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
bracket (10) (43.0-47.4 N·m)
Cooling bracket Bolthole 63, 66 Bolt (2), Nuts (3) 380-420 lb in. (a) (b)
(11) (43.0-47.4 N·m)
Cooling bracket Bolthole 71, 74, 76 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
(12) (43.0-47.4 N·m)
Air/Oil bracket (13) Bolthole 78, 80 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
(43.0-47.4 N·m)
Air/Oil bracket (14) Bolthole 87, 89 Bolts (2), Nuts (3) 380-420 lb in. (a) (b)
(43.0-47.4 N·m)
Balance piston air Air/Oil bracket (1) Bolts (16), Nuts 55-70 lb in. (a)
bracket (15) (17) (6.3-7.9 N·m)
Cooling bracket Balance piston air Bolts (19), 55-70 lb in. (a)
(18) bracket (15) Washers (20) (6.3-7.9 N·m)
Cooling bracket Cooling bracket (4) Bolts (16), 55-70 lb in. (a)
(36) Nuts (17) (6.3-7.9 N·m)
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Table 1. HPC/CRF Flange Brackets (See figure 1.) (Continued)
Attach To Secure
Item Item With Torque Notes
Cooling bracket Cooling bracket Bolts (19), 55-70 lb in. (a)
(21) (36) Washers (20) (6.3-7.9 N·m)
Electrical bracket Cooling air bracket Bolts (23), 55-70 lb in. (a)
(22) (5) Nuts (17) (6.3-7.9 N·m)
Cooling bracket Air/Oil bracket (6) Bolts (26), 55-70 lb in. (a)
(25), Tray mount Nuts (17) (6.3-7.9 N·m)
bracket (28),
Bridge bracket (24)
Cooling bracket Cooling bracket Bolts (19), 55-70 lb in. (a)
(27) (25) Washers (20) (6.3-7.9 N·m)
Cooling bracket Air/Oil bracket (7) Bolts (16), 55-70 lb in. (a)
(29) (Initial Nuts (17) (6.3-7.9 N·m)
configuration)
Cooling bracket Cooling bracket Bolts (19), 55-70 lb in. (a)
(30) (Initial (29) Washers (20) (6.3-7.9 N·m)
configuration)
Tray mount bracket Air/Oil bracket (8) Bolts (19), 55-70 lb in. (a)
(31) Nuts (17) (6.3-7.9 N·m)
Tray mount bracket Tray mount bracket Bolts (19) 55-70 lb in. (a)
(31) (28) (6.3-7.9 N·m)
Cooling bracket Cooling bracket Bolts (16), 55-70 lb in. (a)
(32) (12) Nuts (17) (6.3-7.9 N·m)
Cooling bracket Cooling bracket Bolts (19), 55-70 lb in. (a)
(33) (32) Washers (20) (6.3-7.9 N·m)
Cooling bracket Air/oil bracket (13) Bolts (16), 55-70 lb in. (a)
(34) Nuts (17) (6.3-7.9 N·m)
Cooling bracket Cooling bracket Bolts (19), 55-70 lb in. (a)
(35) (34) Washers (20) (6.3-7.9 N·m)
HPC flange bracket Air/oil bracket (7) Bolts (38), 55-70 lb in. (a)
(37) Nuts (39) (6.2-7.9 N·m)
Stage 7 cooling air Cooling bracket Bolts (38), 55-70 lb in. (a)
tube bracket (40) (12) Nuts (39) (6.2-7.9 N·m)
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Table 1. HPC/CRF Flange Brackets (See figure 1.) (Continued)
Attach To Secure
Item Item With Torque Notes
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(b) Boltheads face aft.
(c) Boltheads face forward.
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Figure 2. CRF/HPT Flange Brackets (Sheet 1 of 2)
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Figure 2. CRF/HPT Flange Brackets (Sheet 2 of 2)
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Table 2. CRF/HPT Flange Brackets (See figure 2.)
Attach To Secure
Item Item With Torque Notes
LPT bracket (1) Bolthole 131, 132, Bolts (2), Nuts (3) 210-230 lb in. (a)
133 (23.8-25.9 N·m)
Fuel/Steam bracket Bolthole 23, 24, 25 Bolts (2), Nuts (3) 210-230 lb in. (a)
(4) (23.8-25.9 N·m)
HP recoup bracket Bolthole 45, 46, 47 Bolts (2), Nuts (3) 210-230 lb in. (a)
(5) (23.8-25.9 N·m)
Cooling bracket (6) Bolthole 51, 52, 53 Bolts (2), Nuts (3) 210-230 lb in. (a)
(Initial (23.8-25.9 N·m)
configuration)
Lube tray bracket Bolthole 60, 65 Bolts (2), Nuts (3) 210-230 lb in. (a)
(7) (23.8-25.9 N·m)
Recoup bracket (8) Bolthole 80, 85 Bolts (2), Nuts (3) 210-230 lb in. (a)
(23.8-25.9 N·m)
Fuel bracket (9) Bolthole 110, 111, Bolts (2), Nuts (3) 210-230 lb in. (a)
112 (23.8-25.9 N·m)
HP recoup bracket Bolthole 113, 114, Bolts (2), Nuts (3) 210-230 lb in. (a)
(10) 115 (23.8-25.9 N·m)
Recoup bracket Recoup bracket (8) Bolts (12), 210-230 lb in. (a) (b)
(11) Washers (13) (23.8-25.9 N·m)
LP cooling support Boltholes 50, 51, Bolts (15), 210-230 lb in. (a)
bracket (14) 52, 53 Nuts (16) (23.8-25.9 N·m)
LP cooling support Boltholes 106, 107, Bolts (15), 210-230 lb in. (a)
bracket (17) 108, 109 Nuts (16) (23.8-25.9 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(b) Nutplates face aft.
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Figure 3. CRF Aft Case to CRF Brackets (Sheet 1 of 2)
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Figure 3. CRF/HPT Flange Brackets (Sheet 2 of 2)
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Table 3. CRF Aft Case To CRF Brackets (See figure 3.)
Attach To Secure
Item Item With Torque Notes
Electrical bracket Fuel nozzle 1 Bolts (2) 110-120 lb in. (a) (b) (c)
(1) (12.5-13.5 N·m)
UV detector Fuel nozzle 4 Bolts (2) 110-120 lb in. (a) (b) (c)
bracket (3) (12.5-13.5 N·m)
Electrical bracket Fuel nozzle 6 Bolts (2) 80-90 lb in. (a) (b) (c)
(4) (9.0-10.2 N·m)
Cooling bracket (5) Fuel nozzle 8 Bolts (2) 80-90 lb in. (a) (b) (c)
(9.0-10.2 N·m)
Cooling bracket (6) Fuel nozzle 10 Bolts (2) 80-90 lb in. (a) (b) (c)
(9.0-10.2 N·m)
HP recoup bracket Fuel nozzle 13 Bolts (2) 80-90 lb in. (a) (b) (c)
(7) (9.0-10.2 N·m)
Cooling bracket (8) Fuel nozzle 14 Bolts (2) 80-90 lb in. (a) (b) (c)
(Initial (9.0-10.2 N·m)
configuration)
Lube bracket (9) Fuel nozzle 15 Bolts (2) 80-90 lb in. (a) (b) (c)
(9.0-10.2 N·m)
Lube bracket (10) Fuel nozzle 17 Bolts (2) 80-90 lb in. (a) (b) (c)
(9.0-10.2 N·m)
Lube bracket (11) Fuel nozzle 20 Bolts (2) 80-90 lb in. (a) (b) (c)
(9.0-10.2 N·m)
Cooling bracket Fuel nozzle 24 Bolts (2) 80-90 lb in. (a) (b) (c)
(12) (9.0-10.2 N·m)
Cooling bracket Fuel nozzle 25 Bolts (2) 80-90 lb in. (a) (b) (c)
(13) (9.0-10.2 N·m)
LPT cooling Fuel nozzle 26 Bolts (2) 80-90 lb in. (a) (b) (c)
bracket (23) (9.0-10.2 N·m)
UV detector Fuel nozzle 27 Bolts (2) 80-90 lb in. (a) (b) (c)
bracket (14) (9.0-10.2 N·m)
HP recoup bracket Fuel nozzle 28 Bolts (2) 80-90 lb in. (a) (b) (c)
(15) (9.0-10.2 N·m)
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Table 3. CRF Aft Case To CRF Brackets (See figure 3.) (Continued)
Attach To Secure
Item Item With Torque Notes
UV detector UV detector Bolts (20), 55-70 lb in. (b) (d)
bracket (16) bracket (3) Washers (18), (6.2-7.9 N·m)
Nuts (19)
CRF flame sight Compressor rear 315-345 lb in. (b)
(21) frame (35.6-39.0 N·m)
UV detector UV detector Bolts (20), 55-70 lb in. (b)
bracket (17) bracket (14) Washers (18), (6.3-7.9 N·m)
Nuts (19)
CRF flame sight Compressor rear 315-345 lb in. (b)
(22) frame (35.6-39.0 N·m)
NOTES:
(a) Bolts are fuel nozzle attaching bolts.
(b) Lubricate threads and washer faces of bolts using thread lubricant.
(c) Safety-wire using R297P04 safety wire.
(d) See figure 7, SWP 1913 04.
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Figure 4. Core Module Brackets (Sheet 1 of 2)
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Figure 4. Core Module Brackets (Sheet 2 of 2)
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Table 4. Core Module Brackets (See figure 4.)
Attach To Secure
Item Item With Torque Notes
B-sump bracket (1) HPC case Bolts (2) 55-70 lb in. (a) (b)
(6.3-7.9 N·m)
B-sump bracket (3) HPC case Bolts (2) 55-70 lb in. (a) (b)
(6.3-7.9 N·m)
Vent bracket (4) HPC case Bolts (5) 55-70 lb in. (a) (b)
(6.3-7.9 N·m)
Vent bracket (6) HPC case Bolts (5) 55-70 lb in. (a) (b)
(6.3-7.9 N·m)
Vent bracket (7) HPC case Bolts (8) 55-70 lb in. (a) (b)
(6.3-7.9 N·m)
Vent bracket (9) HPC case Bolts (5) 55-70 lb in. (a) (b)
(6.3-7.9 N·m)
Electrical bracket HPC case Bolts (11) 55-70 lb in. (a) (b)
(10) (6.3-7.9 N·m)
Flange cooling HPC case Bolts (15) 55-70 lb in. (a) (b)
bracket (12) (6.3-7.9 N·m)
Sump bracket (13) Flange cooling Bolts (14) 55-70 lb in. (a) (b)
bracket (12) (6.3-7.9 N·m)
Electrical bracket HPC case Bolts (11) 55-70 lb in. (a) (b)
(16) (6.3-7.9 N·m)
Bridge bracket (17) Bridge bracket Bolts (18) 55-70 lb in. (a) (b)
(24, figure 1) (6.3-7.9 N·m)
Bridge bracket (17) Electrical bracket Bolts (18) 55-70 lb in. (a) (b)
(16) (6.3-7.9 N·m)
Electrical bracket Electrical bracket Bolts (18) 55-70 lb in. (a) (b)
(19) (10) (6.3-7.9 N·m)
Electrical bracket Electrical bracket Bolts (18) 55-70 lb in. (a) (b)
(19) (16) (6.3-7.9 N·m)
No. 3 electrical Electrical bracket Bolts (21) 55-70 lb in. (a) (b)
interface panel (20) (10) (6.3-7.9 N·m)
20 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Table 4. Core Module Brackets (See figure 4.) (Continued)
Attach To Secure
Item Item With Torque Notes
No. 3 electrical Electrical bracket Bolts (18) 55-70 lb in. (a) (b)
interface panel (20) (16) (6.3-7.9 N·m)
No. 3 electrical Electrical bracket Bolts (18) 55-70 lb in. (a) (b)
interface panel (20) (19) (6.3-7.9 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts using thread lubricant.
(b) Safety-wire using R297P04 safety wire.
Change 4 21
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Figure 5. HPT Tubing, Original Configuration
22 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Table 5. HPT Tubing, Original Configuration (See figure 5.)
Attach To Secure
Item Item With Torque Notes
Seal ring (1), High pressure Bolts (3) 55-70 lb in. (a)
Baseplate (2) turbine (eight (6.3-7.9 N·m)
places)
Seal ring (4), Baseplate (2) Bolts (6) 55-70 lb in. (a)
Cooling air tube (8) (6.3-7.9 N·m)
Seal ring (4), Baseplate (2) Bolts (6) 55-70 lb in. (a)
Check valve (7) (6.3-7.9 N·m)
Cooling air tube (8) Check valve (7) Coupling nut 40-50 lb ft (b)
(54.3-67.8 N·m)
Seal ring (4), Baseplate (2) Bolts (6) 55-70 lb in. (a)
Check valve (9) (6.3-7.9 N·m)
Seal ring (4), Baseplate (2) Bolts (6) 55-70 lb in. (a)
Cooling air (6.3-7.9 N·m)
tube (11)
Cooling air Check valve (9) Coupling nut 40-50 lb ft (b)
tube (11) (54.2-67.8 N·m)
Seal ring (4), Baseplate (2) Bolts (6) 55-70 lb in. (a)
Cooling air (6.3-7.9 N·m)
tube (14)
Seal ring (4), Baseplate (2) Bolts (6) 55-70 lb in. (a)
Check valve (13) (6.3-7.9 N·m)
Cooling air Check valve (13) Coupling nut 40-50 lb ft (b)
tube (14) (54.2-67.8 N·m)
Seal ring (4), Baseplate (2) Bolts (6) 55-70 lb in. (a)
Check valve (15) (6.3-7.9 N·m)
Seal ring (4), Baseplate (2) Bolts (6) 55-70 lb in. (a)
Cooling air (6.3-7.9 N·m)
tube (17)
Cooling air Check valve (15) Coupling nut 40-50 lb ft (b)
tube (17) (54.2-67.8 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts using thread lubricant.
(b) Safety-wire.
Change 4 23
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Figure 5A. HPT Tubing, Current Configuration
24 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Table 5A. HPT Tubing, Current Configuration (See figure 5A.)
Attach To Secure
Item Item With Torque Notes
Ring seal (1), High pressure Bolts (3) 60-70 lb in. (a)
Baseplate (2) turbine (eight (6.8-7.9 N·m)
places)
Ring seal (4), Baseplate (2) Bolts (6) 60-70 lb in. (a)
Check valve (5) (6.8-7.9 N·m)
Ring seal (4), Baseplate (2) Bolts (6) 60-70 lb in. (a)
Check valve (7) (6.8-7.9 N·m)
Cooling air tube (8) Check valve (7) Coupling nut (19) 40-50 lb ft (b)
(55-67 N·m)
Cooling air tube (8), Check valve (5) Coupling nut (18) 55-70 lb in.
Ring seal (20) (6.3-7.9 N·m)
Ring seal (4), Baseplate (2) Bolts (6) 60-70 lb in. (a)
Check valve (9) (6.8-7.9 N·m)
Ring seal (4), Baseplate (2) Bolts (6) 60-70 lb in. (a)
Check valve (10) (6.8-7.9 N·m)
Cooling air tube (11) Check valve (9) Coupling nut (19) 40-50 lb ft (b)
(55-67 N·m)
Cooling air tube (11), Check valve (10) Coupling nut (18) 55-70 lb in.
Ring seal (20) (6.3-7.9 N·m)
Ring seal (4), Baseplate (2) Bolts (6) 60-70 lb in. (a)
Check valve (12) (6.8-7.9 N·m)
Ring seal (4), Baseplate (2) Bolts (6) 60-70 lb in. (a)
Check valve (13) (6.8-7.9 N·m)
Cooling air tube (14) Check valve (13) Coupling nut (19) 40-50 lb ft (b)
(55-67 N·m)
Cooling air tube (14), Check valve (12) Coupling nut (18) 55-70 lb in.
Ring seal (20) (6.3-7.9 N·m)
Ring seal (4), Baseplate (2) Bolts (6) 60-70 lb in. (a)
Check valve (15) (6.8-7.9 N·m)
Seal ring (4), Baseplate (2) Bolts (6) 60-70 lb in. (a)
Check valve (16) (6.8-7.9 N·m)
Change 4 25
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Table 5A. HPT Tubing, Current Configuration (See figure 5A.) (Continued)
Attach To Secure
Item Item With Torque Notes
Cooling air tube (17) Check valve (15) Coupling nut (19) 40-50 lb ft (b)
(55-67 N·m)
Cooling air tube (17), Check valve (16) Coupling nut (18) 55-70 lb in.
Ring seal (20) (6.3-7.9 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts using thread lubricant.
(b) Safety-wire.
26 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 1 of 13)
Change 4 27
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 2 of 13)
28 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 3 of 13)
Change 4 29
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 4 of 13)
30 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 5 of 13)
Change 4 31
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 6 of 13)
32 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 7 of 13)
Change 4 33
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 8 of 13)
34 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 9 of 13)
Change 4 35
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 10 of 13)
36 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 11 of 13)
Change 4 37
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 12 of 13)
38 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Figure 6. Core Module Tubing and Clamping (Sheet 13 of 13)
Change 4 39
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Table 6. Core Module Tubing and Clamping (See figure 6.)
Attach To Secure
Item Item With Torque Notes
Gasket (1), CRF strut 9 Bolts (3), Nuts (4) 55-70 lb in. (a)
B-sump air tube (2) (6.3-7.9 N·m)
B-sump air tube (2) Sump bracket Retaining strap (5), 55-70 lb in. (a)
(13, figure 4) Bolts (6), Washers (6.3-7.9 N·m)
(7), Nuts (4)
B-sump air tube (2) B-sump bracket Retaining straps (8, 55-70 lb in. (a)
(1, figure 4) 9), Bolts (6), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Seal ring (10), LPT Stage 8 bleed air Coupling (12) 40 lb in.
air tube (11) (Initial manifold (4.52 N·m)
configuration)
LPT air tube (11) Cooling bracket Retaining strap 55-70 lb in. (a)
(Initial (71) (13), Bolts (6), (6.3-7.9 N·m)
configuration) Nuts (4)
LPT air tube (11) Cooling bracket Retaining strap 55-70 lb in. (a)
(Initial (72) (13), Bolts (6), (6.3-7.9 N·m)
configuration) Washers (7),
Nuts (4)
Gasket (14), LPT LPT air tube (15) Bolts (16), 55-70 lb in. (a)
air tube (11) (Initial Nuts (17), (6.3-7.9 N·m)
configuration) Orifice plate (18)
LPT air tube (15) Bracket (73) Retaining strap 55-70 lb in. (a)
(13), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Seal ring (20), Stage 11 bleed air Coupling (22) 45 lb in.
HPT air tube (21) manifold (5.1 N·m)
HPT air tube (21) Check valve Coupling nut 40-50 lb ft (b)
(7, figure 5) (54.2-67.8 N·m)
HPT air tube (21) Cooling bracket Retaining strap 55-70 lb in. (a)
(35, figure 1) (23), Bolts (6) (6.3-7.9 N·m)
40 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Table 6. Core Module Tubing and Clamping (See figure 6.) (Continued)
Attach To Secure
Item Item With Torque Notes
HPT air tube (21) Cooling bracket Retaining strap 55-70 lb in. (a)
(13, figure 3) (23), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Gasket (25), HP Compressor rear Bolts (3), Nuts (4) 55-70 lb in. (a)
recoup air tube (24) frame (6.3-7.9 N·m)
HP recoup air tube HP recoup bracket Retaining strap 55-70 lb in. (a) (c)
(24) (15, figure 3) (26), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
HP recoup air tube HP recoup bracket Retaining strap 55-70 lb in. (a)
(24) (10, figure 2) (26), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Seal ring (20), Stage 11 bleed air Coupling (22) 45 lb in.
HPT air tube (27) manifold (5.1 N·m)
HPT air tube (27) Check valve Coupling nut 40-50 lb ft (b)
(9, figure 5) (54.2-67.8 N·m)
HPT air tube (27) Cooling bracket Retaining strap 55-70 lb in. (a)
(33, figure 1) (23), Bolts (6) (6.3-7.9 N·m)
HPT air tube (27) Cooling bracket Retaining strap 55-70 lb in. (a)
(12, figure 3) (28), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Gasket (30), Compressor Bolts (31), Nuts (4) 55-70 lb in. (a)
Air manifold (29) discharge ports (6.3-7.9 N·m)
Air manifold (29) Recoup bracket Retaining strap 55-70 lb in. (a)
(11, figure 2) (32), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Gasket (34), Air tube (36) Coupling (35) 45 lb in.
Supply tube (33) (5.1 N·m)
Change 4 41
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Table 6. Core Module Tubing and Clamping (See figure 6.) (Continued)
Attach To Secure
Item Item With Torque Notes
Air tube (36) Bracket (74) Retaining strap 55-70 lb in. (a)
(37), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Supply tube (33) B-sump bracket Retaining strap 55-70 lb in. (a)
(3, figure 4) (37), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Supply tube (33) Bracket (75) Retaining strap 55-70 lb in. (a)
(37), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Gasket (34), Supply tube (33) Coupling (35) 45 lb in.
Supply tube (38) (5.1 N·m)
Supply tube (38) Bracket (76) Retaining strap 55-70 lb in. (a)
(37), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Supply tube (38) Bracket (77) Retaining strap 55-70 lb in. (a)
(37), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Supply tube (38) Bracket (78) Retaining strap 55-70 lb in. (a)
(37), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Seal ring (20), Stage 11 bleed air Coupling (22) 45 lb in.
HPT air tube (39) manifold (5.1 N·m)
HPT air tube (39) Check valve Coupling nut 40-50 lb ft (b)
(15, figure 5) (54.2-67.8 N·m)
HPT air tube (39) Cooling bracket Retaining strap 55-70 lb in. (a)
(21, figure 1) (40), Bolts (6) (6.3-7.9 N·m)
42 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Table 6. Core Module Tubing and Clamping (See figure 6.) (Continued)
Attach To Secure
Item Item With Torque Notes
HPT air tube (39) Cooling bracket Retaining strap 55-70 lb in. (a)
(5, figure 3) (40), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Seal ring (20), Stage 11 bleed air Coupling (22) 45 lb in.
HPT air tube (41) manifold (5.1 N·m)
HPT air tube (41) Check valve Coupling nut 40-50 lb ft (b)
(13,figure 5) (54.2-67.8 N·m)
HPT air tube (41) Cooling bracket Retaining strap 55-70 lb in. (a)
(27, figure 1) (40), Bolts (16) (6.3-7.9 N·m)
HPT air tube (41) Cooling bracket Retaining strap 55-70 lb in. (a)
(6, figure 3) (40), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
Gasket (43), HP Compressor rear Bolts (3), Nuts (4) 55-70 lb in. (a)
recoup tube (42) frame (6.3-7.9 N·m)
HP recoup tube HP recoup bracket Retaining strap 55-70 lb in. (a)
(42) (7, figure 3) (70), Bolts (19), (6.3-7.9 N·m)
Washer (7),
Nuts (4)
HP recoup tube HP recoup bracket Retaining strap 55-70 lb in. (a)
(42) (5, figure 2) (70), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
B and C supply oil Compressor rear Coupling nut 650-770 lb in.
tube (44) frame (73.4-87.0 N·m)
B and C supply oil Lube bracket Split bushing (45), 55-70 lb in. (a)
tube (44) (11, figure 3) Clamp (46), Bolt (6.3-7.9 N·m)
(19), Nut (4)
B and C supply oil Lube bracket Split bushing (45), 55-70 lb in. (a)
tube (44) (10, figure 3) Clamp (46), Bolt (6.3-7.9 N·m)
(19), Nut (4)
Change 4 43
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 02
Table 6. Core Module Tubing and Clamping (See figure 6.) (Continued)
Attach To Secure
Item Item With Torque Notes
Gasket (47), C Compressor rear Retainer plate (49), 55-70 lb in. (a)
scavenge oil tube frame Bolts (50) (6.3-7.9 N·m)
(48)
C scavenge oil tube Lube bracket Split bushing (51), 55-70 lb in. (a)
(48) (10, figure 3) Clamp (52), (6.3-7.9 N·m)
Bolt (19)
C scavenge oil tube Lube bracket Split bushing (51), 55-70 lb in. (a)
(48) (9, figure 3) Clamp (52), (6.3-7.9 N·m)
Bolt (19)
Gasket (53), Compressor rear Retainer plate (55), 55-70 lb in. (a)
B scavenge oil tube frame Bolts (50) (6.3-7.9 N·m)
(54)
B scavenge oil tube Lube bracket Split bushing (56), 55-70 lb in. (a)
(54) (9, figure 3) Clamp (57), (6.3-7.9 N·m)
Bolt (19)
Gasket (58), LPT air tube (60) Orifice plate (61), 55-70 lb in. (a)
LPT air tube (59) Bolts (16), (6.3-7.9 N·m)
Nuts (17)
LPT air tube (59) Cooling bracket Retaining strap 55-70 lb in. (a)
(6, figure 2) (62), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
LPT air tube (59) Cooling bracket Retaining strap 55-70 lb in. (a)
(8, figure 3) (62), Bolts (19), (6.3-7.9 N·m)
Washers (7),
Nuts (4)
LPT air tube (60) Cooling bracket Retaining strap 55-70 lb in. (a)
(Initial (30, figure 1) (62), Bolts (19), (6.3-7.9 N·m)
configuration) Washers (7),
Nuts (4)
Gasket (63), LPT Stage 8 adapter Bolts (65) 55-70 lb in. (a)
air tube (60) (Initial (64) (6.3-7.9 N·m)
configuration)
44 Change 4
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 02
Table 6. Core Module Tubing and Clamping (See figure 6.) (Continued)
Attach To Secure
Item Item With Torque Notes
Seal ring (66), Stage 8 bleed air Coupling (67) TBD
Stage 8 adapter (64) manifold
(Initial
configuration)
Gasket (68), Stage 8 adapter Bolts (65) 55-70 lb in. (a)
Cover plate (69) (64) (6.3-7.9 N·m)
(Initial
configuration)
Metal seal ring Stage 7 port (82) Clamp coupling 40 lb in. (4.6 N·m) (d)
(80), Stage 7 port (79)
cover (81) (Initial
configuration)
Seal fitting (84), Instrumentation 135-155 lb in. (b)
Machine plug (85) port (86) (15.5-17.5 N·m)
LPT air tube (60) HPC aft flange Retaining strap Finger-tight 55-70 (a)
bracket (87) (88), Bolts (89) lb in. (6.2-7.9 N·m)
Square gasket (90), Front frame Bolts (91) Finger-tight
Air tube (36) (b)
Air adapter (98), HPC stage 11 port Clamp coupling 110-125 lb in. (a)
Metal seal ring (99) (100) nut (12.4-14.1 N·m)
(Initial
configuration)
Machine plug (102) Instrumentation Seal fitting (101) 135-155 lb in. (b)
port (103) (15.3-17.5 N·m)
Oil supply bracket Lube tray bracket Bolts (104) 55-70 lb in. (6.2-7.9 (a)
(105) (7, figure 2) N·m)
Oil supply bracket Tray mount bracket Bolts (104) 55-70 lb in. (6.2-7.9 (a)
(105) (31, figure 1) N·m)
LPT cooling air Cooling Bolt (6), restraining (a)
tube (92) bracket (71) strap (13)
LPT cooling air HPT case port Metal seal ring 40 lb in.
tube (92) (93), Coupling (12) (4.5 N·m)
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SWP 1913 02
Table 6. Core Module Tubing and Clamping (See figure 6.) (Continued)
Attach To Secure
Item Item With Torque Notes
Plug (94) Instrumentation Boss and fitting 135-155 lb in.
port seal (95) (15.3-17.5 N·m) (b)
LPT cooling air LPT cooling air Bolts (16) Finger-tight
tube (92) tube (15) Gasket (14), 110-130 lb in.
Orifice plate (18), (11.3-14.7 N·m)
Nuts (17)
LPT cooling air Bracket Bolts (106), Nut
tube (92) (17, figure 2) (4), Washer (7),
Restraining
strap (107)
LPT cooling air Support bracket Bolts (19),
tube (96) (37, figure 1) Restraining
strap (62) (a)
LPT cooling air HPC case port Metal seal ring 40 lb in.
tube (96) (93), Coupling (12) (4.5 N·m)
Plug (94) Instrumentation Boss and fitting 135-155 lb in.
port seal (95) (15.3-17.5 N·m) (b)
LPT cooling air LPT cooling air Bolts (16), Finger-tight
tube (96) tube (59) Gaskets (68), 110-130 lb in.
Orifice plate (61), (11.3-14.7)
Nuts (17)
Stage 8 cover Stage 8 adapter Coupling (67) TBD
plate (97), Metal (64)
seal ring (66)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts/plugs using thread lubricant.
(b) Safety-wire.
(c) See figure 7, SWP 1913 04.
(d) Safety-wire to adjacent jamnut.
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Figure 7. CRF Accelerometer Integral Lead
Table 7. CRF Accelerometer Integral Lead (See figure 7.)
Attach To Secure
Item Item With Torque Notes
Accelerometer Accelerometer Clamp (2), Bolt (3), 55-70 lb in. (a) (b)
integral lead (1) bracket Nut (4) (6.3-7.9 N·m)
(9, figure 1)
Bridge bracket Clamp (5), Bolt (3) 55-70 lb in. (a) (b)
(17, figure 4) (6.3-7.9 N·m)
Electrical bracket Clamp (6), Bolt (3) 55-70 lb in. (a) (b)
(19, figure 4) (6.3-7.9 N·m)
No. 3 electrical Jamnut Hand-tighten, then (c)
interface panel 1/4 to 1/2 turn
(20, figure 4)
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Table 7. CRF Accelerometer Integral Lead (See figure 7.) (Continued)
Attach To Secure
Item Item With Torque Notes
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(b) Lead may be spiral wrapped using silicone tape in the area of clamps and 0.50 inch
(12.7 mm) on either side of clamp to provide positive lead clamping as required.
(c) Safety-wire to adjacent jamnut.
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5SWP 1913 03
SUBORDINATE WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE TURBINE (LPT) MODULE EXTERNAL
TUBING, HARNESSES, AND CLAMPING
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 26
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 25 ...... 5
26 Blank . . . . . . 5
Alphabetical Index
Subject Page
Air Manifold Installation ............................................................................................................ 4
Low Pressure Turbine Module Brackets Installation.................................................................. 4
Low Pressure Turbine Module Electrical Leads Installation ...................................................... 4
Low Pressure Turbine Module Tubing and Clamping Installation............................................. 4
Low Pressure Turbine/Turbine Rear Frame Flange Brackets Installation .................................. 4
Replacing Manifold Bracket ....................................................................................................... 4
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1. Introduction.
A. This subordinate work package contains information concerning installation of the low pres-
sure turbine (LPT) module and turbine rear frame (TRF) external, tubing,
harnesses, and clamping.
B. The following general instructions shall be met any time tubing, electrical leads,
harnesses, or cables are disturbed:
(1) Unless otherwise specified, the bend radii for an electrical lead, cable, or harness must
exhibit a smooth transition. No kinks allowed.
(2) Electrical connections of leads and harnesses shall conform to the following assembly
points:
(a) Engage the connector with its mating interface and turn knurled coupling ring, while
wiggling the backshell assembly.
(b) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4 to 1/2 turn, or until plier slippage occurs.
(c) Check for full seating by wiggling accessory assembly. There shall be no movement
with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(d) Repeat substeps (b) and (c), as required. It may be necessary to loosen lead clamps
that restrict mating.
(3) Torque all remaining nuts of misalignment fittings as follows:
Tube Size OD Torque
(inches) (mm) (lb ft) (N·m)
0.75-1.0 (19.0-25.4) 24-26 (32.5-35.2)
1.125-1.50 (28.57-38.1) 20-40 (27.1-54.2)
1.625-2.0 (41.27-50.8) 40-50 (54.2-67.8)
2.125 and up (53.9 and up) 50-60 (67.8-81.3)
(4) Unless otherwise noted, install all bolts with boltheads forward.
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(5) If any external tube or manifold does not fit in the free state at assembly within
0.060 inch (1.52 mm) and is known to be within manufacturing tolerance, it shall be
modified by bending as required. After bending to obtain the required free-state fit, the
following shall apply:
(a) Part shall conform to original specification and pressure requirements.
(b) Bend radii shall not be less than manufacturing limits.
(c) Coupling nuts shall thread freely by hand.
(d) End flange fittings shall seat flush within 0.005 inch (0.12 mm).
(e) End points of tube or manifold shall align with mating connector with 0.060 inch
(1.52 mm) in all planes.
(f) A minimum clearance of 0.125 inch (3.17 mm) shall be maintained between tube
OD and adjacent parts.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixturing Clamps 2C14754G01
Teflon-jawed pliers Local Purchase
4. Consumable Material.
Nomenclature Specification
Penetrating Oil L1 Liquid Wrench or
Dag 2404
(GE Spec. A50TF54)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Silicone Tape MIL-I-46852
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Due to the variety of gaskets, packings, seals, etc. used during installation of external
tubing, expendable materials are not listed. Reference GEK 105060, Illustrated Parts Breakdown
(IPB), for required parts.
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6. Low Pressure Turbine/Turbine Rear Frame Flange Brackets Installation.
See figure 1 and table 1.
7. Air Manifold Installation.
See figure 2 and table 2.
8. Low Pressure Turbine Module Brackets Installation.
See figure 3 and table 3.
9. Low Pressure Turbine Module Tubing and Clamping Installation.
See figure 4 and table 4.
10. Low Pressure Turbine Module Electrical Leads Installation.
See figure 5 and table 5.
5
4
3
2
1
11. Replacing Manifold Bracket.
See figure 2.
CAUTION
• EXTENDED DWELL PERIOD IS RECOMMENDED TO AVOID
FASTENER BREAKAGE.
• DO NOT ATTEMPT THIS MAINTENANCE IF ADEQUATE
TIME IS NOT AVAILABLE FOR RECOMMENDED PENE-
TRANT DWELL TIME.
A. Liberally soak all fasteners to be removed with penetrating oil. 12-HOUR
MINIMUM DWELL TIME IS RECOMMENDED. Repeated soaking is
recommended throughout the dwell period to maximize penetrant effectiveness.
B. Remove self-locking nuts (9) and bolts (8) securing support links (7) to manifold
bracket (10).
C. Install safety wire through clevis end of support links (7) where bolt (8) was; secure clevis end
link to manifold with safety wire.
D. Remove old manifold bracket (10) from LPT case as follows:
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Figure 1. LPT/TRF Flange Brackets
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Table 1. LPT/TRF Flange Brackets (See figure 1.)
Attach To Secure
Item Item With Torque Notes
Balance piston Boltholes 8, 9, 10 Bolts (2) 400-440 lb in. (a)
bracket (1) (45.2-49.7 N·m)
Balance piston Boltholes 22, 23, Bolts (2) 400-440 lb in. (a)
bracket (3) 24 (45.2-49.7 N·m)
Cable bracket (4) Boltholes 28, 29 Bolts (5), 400-440 lb in. (a)
Self-locking (45.2-49.7 N·m)
nuts (6)
Cable bracket (7), Boltholes 35, 36, Bolts (2) 400-440 lb in. (a)
Balance piston 37 (45.2-49.7 N·m)
bracket (8)
Cable bracket (9) Boltholes 43, 44 Bolts (5), 400-440 lb in. (a)
Self-locking (45.2-49.7 N·m)
nuts (6)
Balance piston Boltholes 48, 49, Bolts (2) 400-440 lb in. (a)
bracket (10) 50 (45.2-49.7 N·m)
Accelerometer Boltholes 51, 52 Bolts (5), 400-440 lb in. (a)
bracket (11) Self-locking (45.2-49.7 N·m)
nuts (6)
Oil scavenge Boltholes 55, 56, Bolts (5), 400-440 lb in. (a)
bracket (12) 57 Self-locking (45.2-49.7 N·m)
nuts (6)
Lube supply Boltholes 61, 62 Bolts (5), 400-440 lb in. (a)
bracket (13) Self-locking (45.2-49.7 N·m)
nuts (6)
Cable bracket (14) Boltholes 66, 67 Bolts (5), 400-440 lb in. (a)
Self-locking (45.2-49.7 N·m)
nuts (6)
Cable bracket (15) Boltholes 71, 72 Bolts (5), 400-440 lb in. (a)
Self-locking (45.2-49.7 N·m)
nuts (6)
Electrical Boltholes 78 Bolts (5), 400-440 lb in. (a)
bracket (16) through 83 Self-locking (45.2-49.7 N·m)
nuts (6)
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Table 1. LPT/TRF Flange Brackets (See figure 1.) (Continued)
Attach To Secure
Item Item With Torque Notes
Cable bracket (17) Boltholes 85, 86 Bolts (5), 400-440 lb in. (a)
Self-locking (45.2-49.7 N·m)
nuts (6)
Cable bracket (18) Boltholes 91, 92 Bolts (5), 400-440 lb in. (a)
Self-locking (45.2-49.7 N·m)
nuts (6)
Cable bracket (19) Boltholes 96, 97 Bolts (5), 400-440 lb in. (a)
Self-locking (45.2-49.7 N·m)
nuts (6)
Cable bracket (20) Boltholes 102, 103 Bolts (5), 400-440 lb in. (a)
Self-locking (45.2-49.7 N·m)
nuts (6)
Balance piston Boltholes 115, 116, Bolts (2) 400-440 lb in. (a)
bracket (21) 117 (45.2-49.7 N·m)
Balance piston Boltholes 124, 125, Bolts (2) 400-440 lb in. (a)
bracket (22) 126 (45.2-49.7 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
CAUTION
• IF BOLT BREAKAGE OCCURS DURING REMOVAL OF
FIRST NUT (11), STOP THIS MAINTENANCE ACTIVITY.
SECOND FASTENER BREAKAGE REQUIRES DEPOT VISIT
TO REPAIR MODULE.
• TWO BOLTS (12) SECURING MANIFOLD BRACKET (10) TO
LPT CASE ARE PRESSED INTO RETAINER (13). ONE NUT
(11) MUST ALWAYS BE INSTALLED TO AVOID DROPPING
RETAINER INTO LPT ASSEMBLY. DROPPING RETAINER
INTO LPT ASSEMBLY REQUIRES DEPOT VISIT TO
REPAIR MODULE.
(1) Remove a single nut (11) completely, then thread nut back on and hand-tighten. Mini-
mum two-thread engagement is required.
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Figure 2. Air Manifold
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Table 2. Air Manifold (See figure 2.)
Attach To Secure
Item Item With Torque Notes
Fixturing clamps, Left side air Wing nuts Finger-tight (a)
2C14754G01 manifold (1),
Right side air
manifold (2)
Gasket (3), Left LPT stator Bolts (4) 90-100 lb in. (b) (c) (d)
side air (10.2-11.3 N·m)
manifold (1)
Gasket (3), Right LPT stator Bolts (4) 90-100 lb in. (c) (d) (e)
side air (10.2-11.3 N·m)
manifold (2)
Left side air Left side air Bolts (5), Nuts (6) 55-70 lb in. (c)
manifold (1) manifold (1), (6.3-7.9 N·m)
Right side air
manifold (2)
Support link (7) Air manifold (1, 2) Bolts (8), Nuts (9) 33-37 lb in. (c) (f) (g)
(3.8-4.1 N·m)
Support link (7) Cooling bracket Bolts (8), Nuts (9) 33-37 lb in. (c) (h) (i) (j)
(3.8-4.1 N·m)
NOTES:
(a) Fixturing clamps align the expansion joints for engine assembly.
(b) Align inlet fitting pointing forward at 10:00 o'clock position (aft looking forward).
(c) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(d) Safety-wire.
(e) Align inlet fitting pointing forward at 4:00 o'clock position (aft looking forward).
(f) Adjustable rod-end of link must be installed to manifold.
(g) Begin support link installation at 12:00 o'clock position and proceed clockwise (aft looking
forward).
(h) Loosen link jamnuts and adjust link to fit up with forward brackets.
(i) Tighten link jamnut to 55-70 lb in. (6.3-7.9 N·m) of torque. Safety-wire jamnut.
(j) Remove fixturing clamps.
(2) Remove second nut (11) completely. Lift and swing manifold bracket (10) over bolt (12)
and to one side, making sure manifold bracket is secured by first nut and bolt.
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Figure 3. LPT Module Brackets (Sheet 1 of 3)
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Figure 3. LPT Module Brackets (Sheet 2 of 3)
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Figure 3. LPT Module Brackets (Sheet 3 of 3)
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Table 3. LPT Module Brackets (See figure 3.)
Attach To Secure
Item Item With Torque Notes
LPT cooling PCC cooling Bolts (4) 29-33 lb in. (c)
bracket (1) manifold (3) (3.3-3.7 N·m)
(6 places)
LPT cooling PCC cooling Bolts (4) 55-70 lb in.
bracket (2) manifold (3) (6.3-7.9 N·m)
(6 places)
LPT damper Bracket (6) Bolts (4) 55-70 lb in.
bracket (5) (5 places) (6.3-7.9 N·m)
LPT damper PCC cooling Bolts (7), 55-70 lb in. (a) (b)
bracket (5) manifold (3) Self-locking (6.3-7.9 N·m)
(5 places) nuts (8)
Cooling damper Bracket (6) Bolts (4) 55-70 lb in.
bracket (9) (5 places) (6.3-7.9 N·m)
Cooling damper PCC cooling Bolts (4) 55-70 lb in. (a) (b)
bracket (9) manifold (3) (6.3-7.9 N·m)
(11 places)
LPT damper Bracket (6) Bolts (4) 55-70 lb in.
bracket (10) (6.3-7.9 N·m)
LPT damper PCC cooling Bolts (11), 55-70 lb in. (a) (b)
bracket (10), manifold (3) Nuts (12) (6.3-7.9 N·m)
Oil supply
bracket (14)
Cooling damper Bracket (6) Bolts (4) 55-70 lb in.
bracket (13) (6.3-7.9 N·m)
Cooling damper PCC cooling Bolts (15) 55-70 lb in. (a) (b)
bracket (13), manifold (3) (6.3-7.9 N·m)
Oil supply
bracket (14)
NOTES:
(a) LPT outer case to PCC cooling manifold clearance shall be a minimum of 0.075 inch
(1.9 mm).
(b) If any tube or manifold does not fit in the free state, within 0.060 inch (1.52 mm), it may be
modified by bending, as required.
(c) This torque value range is non-standard for this bolt at this location.
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Figure 4. LPT Module Tubing and Clamping (Sheet 1 of 3)
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Figure 4. LPT Module Tubing and Clamping (Sheet 2 of 3)
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Figure 4. LPT Module Tubing and Clamping (Sheet 3 of 3)
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Table 4. LPT Module Tubing and Clamping (See figure 4.)
Attach To Secure
Item Item With Torque Notes
Balance piston air TRF (3) Bolts (4), 100-130 lb in. (a)
manifold (1), Self-locking (11.3-14.6 N·m)
Gasket (2) nuts (5)
Balance piston air TRF (3) Bolts (4), 100-130 lb in. (a)
manifold (6), Self-locking (11.3-14.6 N·m)
Gasket (2) nuts (5) (2 places)
Balance piston air Balance piston air Metal seal ring (7), 100-130 lb in. (a)
manifold (1) manifold (6) V-retainer (11.3-14.6 N·m)
coupling (8)
Balance piston air Balance piston Retaining 50-70 lb in. (a)
manifold (1) bracket (21, strap (10), (6.3-7.9 N·m)
figure 1) Bolts (11)
Balance piston air Balance piston Retaining 50-70 lb in. (a)
manifold (1) bracket (22, strap (10), (6.3-7.9 N·m)
figure 1) Bolts (11)
Balance piston air Balance piston Retaining 50-70 lb in. (a)
manifold (1) bracket (1, strap (10), (6.3-7.9 N·m)
figure 1) Bolts (11)
Balance piston air Balance piston Retaining 50-70 lb in. (a)
manifold (6) bracket (3, strap (10), (6.3-7.9 N·m)
figure 1) Bolts (11)
Balance piston air Balance piston Retaining 50-70 lb in. (a)
manifold (6) bracket (8, strap (10), (6.3-7.9 N·m)
figure 1) Bolts (11)
Balance piston air Balance piston Retaining 50-70 lb in. (a)
manifold (6) bracket (10, strap (10), (6.3-7.9 N·m)
figure 1) Bolts (11)
NOTES:
(a) If any tube or manifold does not fit in the free state, within 0.060 inch (1.52 mm), it may be
modified by bending, as required.
(3) Thread removed nut (11) back on and hand-tighten. Minimum two-thread engagement is
required.
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Figure 5. LPT Module Electrical Leads (Sheet 1 of 3)
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Figure 5. LPT Module Electrical Leads (Sheet 2 of 3)
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Figure 5. LPT Module Electrical Leads (Sheet 3 of 3)
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Table 5. LPT Module Electrical Leads (See figure 5)
Attach To Secure
Item Item With Torque Notes
LPT speed Cable bracket Bolts (3) 50-70 lb in. (b) (c)
electrical cable (1) (7, figure 1), (6.3-7.9 N·m)
Cushion clamp (2)
Cable bracket Bolts (3) 50-70 lb in.
(9, figure 1), (6.3-7.9 N·m)
Cushion clamp (2)
Electrical Bolts (3) 50-70 lb in.
bracket (6), (6.3-7.9 N·m)
Cushion clamp (2)
Oil scavenge Bolts (3) 50-70 lb in.
bracket (12, (6.3-7.9 N·m)
figure 1), Cushion
clamp (2)
(2 places)
Lube Supply Bolts (3) 50-70 lb in.
bracket (13, (6.3-7.9 N·m)
figure 1), Cushion
clamp (2)
Cable bracket (14, Bolts (3) 50-70 lb in.
figure 1), Cushion (6.3-7.9 N·m)
clamp (2)
Cable bracket (15, Bolts (3) 50-70 lb in.
figure 1), Cushion (6.3-7.9 N·m)
clamp (2)
Electrical bracket Jamnut Hand-tight, 1/4 to (a)
(16, figure 1) 1/2 turn more
LPT speed Cable bracket (19, Bolts (3) 50-70 lb in. (b) (c)
electrical cable (4) figure 1), Cushion (6.3-7.9 N·m)
clamp (2)
Cable bracket (18, Bolts (3) 50-70 lb in.
figure 1), Cushion (6.3-7.9 N·m)
clamp (2)
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SWP 1913 03
Table 5. LPT Module Electrical Leads (See figure 5) (Continued)
Attach To Secure
Item Item With Torque Notes
Cable bracket (17, Bolts (3) 50-70 lb in.
figure 1), Cushion (6.3-7.9 N·m)
clamp (2)
Electrical bracket Bolts (3) 50-70 lb in.
(16, figure 1), (6.3-7.9 N·m)
Cushion clamp (2)
(2 places)
Electrical bracket Jamnut Hand-tight, 1/4 to (a)
(16,figure 1) 1/2 turn more
High temperature Accelerometer Bolts (3) 50-70 lb in. (a) (b) (c)
accelerometer (5), bracket (11, (6.3-7.9 N·m)
Electrical figure 1)
bracket (6)
High temperature Oil scavenge Bolts (3) 50-70 lb in.
accelerometer (5) bracket (12, (6.3-7.9 N·m)
figure 1), cushion
clamp (7)
(2 places)
Lube supply Bolts (3) 50-70 lb in.
bracket (13, (6.3-7.9 N·m)
figure 1), Cushion
clamp (7)
Cable bracket (14, Bolts (3) 50-70 lb in.
figure 1), Cushion (6.3-7.9 N·m)
clamp (7)
Cable bracket (15, Bolt (3) 50-70 lb in.
figure 1), Cushion (6.3-7.9 N·m)
clamp (7)
Electrical bracket Jamnut Hand-tight, 1/4 to
(16, figure 1) 1/2 turn more
Electrical TMF Bolt (18), 50-70 lb in.
bracket (14) Spacer (19) (6.3-7.9 N·m)
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Table 5. LPT Module Electrical Leads (See figure 5) (Continued)
Attach To Secure
Item Item With Torque Notes
Thermocouple (b)
electrical
harness (8)
Right side air Bolts (10), 50-70 lb in.
manifold (2, Nuts (11) (6.3-7.9 N·m)
figure 2), Cushion
clamp (9)
(4 places)
Right side air Bolts (10), 50-70 lb in.
manifold (2, Nuts (11) (6.3-7.9 N·m)
figure 2), Cushion
clamp (12),
Cushion clamp
(13)
Electrical Bolts (10) 50-70 lb in.
bracket (14), (6.3-7.9 N·m)
Cushion
clamp (12)
Cable bracket (9, Bolts (10) 50-70 lb in.
figure 1), Cushion (6.3-7.9 N·m)
clamp (12)
Electrical bracket Bolts (10) 50-70 lb in.
(16, figure 1), (6.3-7.9 N·m)
Cushion
clamp (12)
(2 places)
Electrical bracket Jamnut Hand-tight, (a)
(16, figure 1) 1/4 to 1/2 turn more
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Table 5. LPT Module Electrical Leads (See figure 5) (Continued)
Attach To Secure
Item Item With Torque Notes
Thermocouple (b)
electrical
harness (15)
Left side air Bolts (10), 50-70 lb in.
manifold (1, Nuts (11) (6.3-7.9 N·m)
figure 2), Cushion
clamp (17)
(11 places)
Left side air Bolts (10), 50-70 lb in.
manifold (1, Nuts (11) (6.3-7.9 N·m)
figure 1), Cushion
clamp (9)
(2 places)
Oil supply bracket Bolts (10), 50-70 lb in.
(14, figure 3), Nuts (11) (6.3-7.9 N·m)
Cushion clamp (9)
Electrical bracket Jamnut Hand-tight, (a)
(16, figure 1) (not shown) 1/4 to 1/2 turn more
NOTES:
(a) Safety-wire.
(b) The bend radii for an electrical lead, cable, or harness shall exhibit a smooth transition. No
kinks allowed.
(c) Cable may be spiral wrapped with silicone tape in the areas of bracket clips or clamps and
0.50 inch (12.7 mm) on either side, beyond the edge of the clip or clamp, to provide positive
lead clamping, as required.
(4) Remove first hand-tightened nut (11). Remove and discard damaged manifold bracket
(10).
(5) Thread removed nut (11) back on and hand-tighten. Minimum two-thread engagement is
required.
E. Install manifold bracket (10) to LPT case as follows:
(1) Remove one of the hand-tightened nuts (11). Discard used nut.
(2) Coat open bolt (12) with thread lubricant, C02-058, on threads only.
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(3) Place new manifold bracket (10) on open bolt (12) and hand-tighten new nut (11). Mini-
mum two-thread engagement is required.
(4) Remove second used hand-tightened nut (11). Discard used nut.
(5) Coat second bolt (12) with thread lubricant, on threads only.
(6) Swing free end of new manifold bracket (10) over second bolt (12) and
hand-tighten new nut (11). Minimum two-thread engagement is required.
(7) Tighten nuts (11) to 55-70 lb in. (6.2-7.9 N·m) of torque.
F. Install securing support links (7) as follows:
(1) Reinstall support links (7) per table 2.
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5SWP 1913 04
SUBORDINATE WORK PACKAGE
TECHNICAL PROCEDURES
ENGINE ASSEMBLY EXTERNAL TUBING,
HARNESSES, AND CLAMPING
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 52
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 51 ...... 4
52 Blank . . . . . . 4
Alphabetical Index
Subject Page
Core Module Final Assembly ..................................................................................................... 4
Engine Assembly Electrical Harnesses Installation.................................................................... 33
Front Frame/HPC Flange Brackets Installation .......................................................................... 4
HPT/LPT Flange Brackets Installation ....................................................................................... 4
Inlet Frame Assembly/LPC Flange Brackets Installation........................................................... 4
LPC Module Final Assembly...................................................................................................... 4
LPT Module Final Assembly ...................................................................................................... 33
VIGV/LPC Flange Brackets Installation .................................................................................... 4
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1. Introduction.
A. This subordinate work package contains information concerning installation of engine assem-
bly external tubing, harnesses, and clamping.
B. The following general instructions shall be met any time tubing, electrical leads,
harnesses, or cables are disturbed:
(1) Unless otherwise specified, the bend radii for an electrical lead, cable, or harness must
exhibit a smooth transition. No kinks allowed.
(2) Electrical connections of heads and harnesses shall conform to the following assembly
points:
(a) Engage the connector with its mating interface and turn knurled coupling ring, while
wiggling the back shell assembly.
(b) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier
slippage occurs.
(c) Check for full seating by wiggling accessory assembly. There shall be no movement
with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(d) Repeat substeps (b) and (c), as required. It may be necessary to loosen lead clamps
that restrict mating.
(3) Torque all remaining nuts of misalignment fittings as follows:
Tube Size OD Torque
(inches) (mm) (lb ft) (N·m)
0.75-1.00 (19.1-25.4) 24-26 (32.5-35.2)
1.125-1.50 (28.58-38.1) 20-40 (27.1-54.2)
1.625-2.00 (41.28-50.8) 40-50 (54.2-67.8)
2.125 and up (54.0 and up) 50-60 (67.8-81.3)
2 Change 4
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(4) Unless otherwise noted, install all bolts with boltheads forward.
(5) If any external tube or manifold does not fit in the free state at assembly within
0.060 inch (1.52 mm), and is known to be within manufacturing tolerance, it shall be
modified by bending as required. After bending, to obtain the required
free-state fit, the following shall apply:
(a) Part shall conform to original specification and pressure requirements.
(b) Bend radii shall not be less than manufacturing limits.
(c) Coupling nuts shall thread freely by hand.
(d) End flange fittings shall seat flush within 0.005 inch (0.13 mm).
(e) End points of tube or manifold shall align with mating connector with
0.060 inch (1.52 mm) in all planes.
(f) A minimum clearance of 0.125 inch (3.18 mm) shall be maintained between tube
OD and adjacent parts.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Front Frame Module External Tubing, Harnesses, and Clamp- SWP 1913 01
ing
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Low Pressure Turbine (LPT) Module External Tubing, Har- SWP 1913 03
nesses, and Clamping
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pliers, Teflon-Jawed Local Purchase
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4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-PRF-23699
(C/I)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Silicone Tape MIL-L-46852
Thread Lubricant GP460
5. Expendable Material.
Due to the variety of gaskets, packings, seals, etc. used during installation of external tubing,
expendable materials are not listed. Refer to Illustrated Parts Breakdown, GEK 105060, for
required parts.
6. VIGV/LPC Flange Brackets Installation.
NOTE
If VIGV kit not installed, then refer to installation of Inlet Frame
Assembly/LPC Flange Bracket, figure 2 and table 2.
See figure 1 and table 1.
1
7. Inlet Frame Assembly/LPC Flange Brackets Installation.
See figure 2 and table 2.
2
8. LPC Module Final Assembly.
See figure 3 and table 3.
(Applies to Gas Turbines with VIGV Assemblies Only)
3
9. Front Frame/HPC Flange Brackets Installation.
See figure 4 and table 4.
4
10. Core Module Final Assembly.
See figure 5 and table 5.
5
11. HPT/LPT Flange Brackets Installation.
See figure 6 and table 6.
6
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Figure 1. VIGV/LPC Flange Brackets
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Table 1. VIGV/LPC Flange Brackets (See figure 1.)
Attach To Secure
Item Item With Torque Notes
Electrical Boltholes 64, 1 Bolts (2), 380-420 lb in. (a)
bracket (1) Washers (3), (42.9-47.5 N·m)
Nuts (4)
Electrical Boltholes 3, 4 Bolts (2), 380-420 lb in. (a)
bracket (5) Washers (3), (42.9-47.5 N·m)
Nuts (4)
Electrical Boltholes 19, 20 Bolts (8), Nuts (4) 380-420 lb in. (a) (b)
bracket (6) (42.9-47.5 N·m)
[Deleted if speed
(XN2) sensor is
deleted]
Mounting Boltholes 19-22 Bolts (8), Nuts (4) 380-420 lb in. (a) (b)
bracket (7) (43.0-47.5 N·m)
Bearing block (9) Mounting Bolts (8), Nuts (10) 360-400 lb in. (a)
bracket (7) (40.7-45.2 N·m)
Angle bracket (11) Boltholes 23, 24 Bolts (2), 380-420 lb in. (a)
Washers (3), (42.9-47.5 N·m)
Nuts (4)
Panel bracket (12) Boltholes 26, 27, 28 Bolts (8), 380-420 lb in. (a)
Washers (3), (42.9-47.5 N·m)
Nuts (4)
IGV bracket (13) Boltholes 29, 30 Bolts (2), 380-420 lb in. (a)
Washers (3), (42.9-47.5 N·m)
Nuts (4)
Angle bracket (14) Boltholes 32, 33 Bolts (2), 380-420 lb in. (a)
Washers (3), (42.9-47.5 N·m)
Nuts (4)
Angle bracket (15) Boltholes 35, 36 Bolts (2), 380-420 lb in. (a)
Washers (3), (42.9-47.5 N·m)
Nuts (4)
Angle bracket (16) Boltholes 38, 39 Bolts (2), 380-420 lb in. (a)
Washers (3), (42.9-47.5 N·m)
Nuts (4)
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Table 1. VIGV/LPC Flange Brackets (See figure 1.) (Continued)
Attach To Secure
Item Item With Torque Notes
Angle bracket (17) Boltholes 41, 42 Bolts (2), 380-420 lb in. (a)
Washers (3), (42.9-47.5 N·m)
Nuts (4)
Angle bracket (18) Boltholes 46, 47 Bolts (2), 380-420 lb in. (a)
Washers (3), (42.9-47.5 N·m)
Nuts (4)
Mounting Boltholes 50, 51, Bolts (8), Nuts (4) 380-420 lb in. (a) (b)
bracket (20) 52, 53 (42.9-47.5 N·m)
Electrical Boltholes 52, 53 Bolts (8), Nuts (4) 380-420 lb in. (a) (b)
bracket (19) (42.9-47.5 N·m)
[Deleted if speed
(XN2) sensor is
deleted]
Bearing block (21) Mounting Bolts (8), Nuts (10) 360-400 lb in. (a)
bracket (20) (40.7-45.2 N·m)
Electrical Boltholes 55, 56 Bolts (2), 380-420 lb in. (a)
bracket (22) Washers (3), (42.9-47.5 N·m)
Nuts (4)
Electrical Boltholes 58, 59 Bolts (2), 380-420 lb in. (a)
bracket (23) Washers (3), (42.9-47.5 N·m)
Nuts (4)
Electrical Boltholes 61, 62 Bolts (2), 380-420 lb in. (a)
bracket (24) Washers (3), (42.9-47.5 N·m)
Nuts (4)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(b) Install mounting brackets on each side of flange.
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Figure 2. Inlet Frame Assembly/LPC Flange Brackets
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Table 2. Inlet Frame Assembly/LPC Flange Brackets (See figure 2.)
Attach To Secure
Item Item With Torque Notes
Panel bracket (1) Boltholes 26, 27, 28 Bolts (14), 380-420 lb in. (a)
Washers (12), (42.9-47.5 N·m)
Nuts (13)
IGV bracket (2) Boltholes 29, 30 Bolts (11), 380-420 lb in. (a)
Washers (12), (42.9-47.5 N·m)
Nuts (13)
Angle bracket (3) Boltholes 32, 33 Bolts (11), 380-420 lb in. (a)
Washers (12), (42.9-47.5 N·m)
Nuts (13)
Angle bracket (4) Boltholes 35, 36 Bolts (11), 380-420 lb in. (a)
Washers (12), (42.9-47.5 N·m)
Nuts (13)
Angle bracket (5) Boltholes 38, 39 Bolts (11), 380-420 lb in. (a)
Washers (12), (42.9-47.5 N·m)
Nuts (13)
Angle bracket (6) Boltholes 41, 42 Bolts (11), 380-420 lb in. (a)
Washers (12), (42.9-47.5 N·m)
Nuts (13)
Angle bracket (7) Boltholes 46, 47 Bolts (11), 380-420 lb in. (a)
Washers (12), (42.9-47.5 N·m)
Nuts (13)
Electrical Boltholes 52, 53 Bolts (14), 380-420 lb in. (a) (b)
bracket (8) Nuts (13) (42.9-47.5 N·m)
Electrical Boltholes 55, 56 Bolts (11), 380-420 lb in. (a)
bracket (9) Washers (12), (42.9-47.5 N·m)
Nuts (13)
Electrical Boltholes 58, 59 Bolts (11), 380-420 lb in. (a)
bracket (10) Washers (12), (42.9-47.5 N·m)
Nuts (13)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(b) Install mounting brackets on each side of flange.
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Figure 3. LPC Module Final Assembly (Sheet 1 of 3)
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Figure 3. LPC Module Final Assembly (Sheet 2 of 3)
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Figure 3. LPC Module Final Assembly (Sheet 3 of 3)
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Table 3. LPC Module Final Assembly (See figure 3.)
Attach To Secure
Item Item With Torque Notes
Channel bracket (1) Panel bracket (9, Bolts (2) 57-67 lb in. (a)
figure 1, (6.5-7.5 N·m)
SWP 1913 01)
Channel bracket (1) IGV bracket (13, Bolts (2) 57-67 lb in. (a)
figure 1) (6.5-7.5 N·m)
Panel bracket (3) Channel bracket (1) Bolts (2) 57-67 lb in. (a)
(6.5-7.5 N·m)
Panel bracket (4) Channel bracket (1) Bolts (2) 57-67 lb in. (a)
(6.5-7.5 N·m)
No. 1 electrical Panel bracket (8, Bolts (2), 57-67 lb in. (a)
interface panel (5) figure 1, Washers (6) (6.5-7.5 N·m)
SWP 1913 01)
No. 1 electrical Panel bracket (12, Bolts (2) 57-67 lb in. (a)
interface panel (5) figure 1) (6.5-7.5 N·m)
No. 1 electrical Panel brackets (3, Bolts (2) 57-67 lb in. (a)
interface panel (5) 4) (6.5-7.5 N·m)
Preformed packing Right VIGV 133-157 lb in. (b)
(7), Reducer (8) actuator rod-end (15.1-17.7 N·m)
port
Preformed packing Right VIGV 133-157 lb in. (b)
(9), Reducer (10) actuator head-end (15.1-17.7 N·m)
port
Preformed packings Oil tube/hose (14) (b)
(11, 12), Drain can
(13)
Oil tube/hose (14) Reducer (8) Coupling nut 262-308 lb in.
(29.7-34.7 N·m)
Drain can (13) Right VIGV Hand-tight (c)
actuator rod-end
port
Preformed packings Oil tube/hose (15) (b)
(11, 12), Drain can
(13)
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Table 3. LPC Module Final Assembly (See figure 3.) (Continued)
Attach To Secure
Item Item With Torque Notes
Oil tube/hose (15) Reducer (10) Coupling nut 262-308 lb in.
(29.7-34.7 N·m)
Drain can (13) Right VIGV Hand-tight (c)
actuator head-end
port
Oil tube/hose (16) Drain cans (13) Coupling nuts 262-308 lb in.
(two places) (29.7-34.7 N·m)
Oil tube/hoses (14, Angle bracket (11, Clamps (17), 57-67 lb in. (a)
15, 16) figure 1) Bolts (18), (6.5-7.5 N·m)
Washers (19)
Preformed packing Left VIGV actuator 133-157 lb in. (b)
(7), Reducer (8) rod-end port (15.1-17.7 N·m)
Preformed packing Left VIGV actuator 133-157 lb in. (b)
(9), Reducer (10) head-end port (15.1-17.7 N·m)
Preformed packings Oil tube/hose (24) (b)
(11, 12), Drain can
(13)
Oil tube/hose (24) Reducer (10) Coupling nut 262-308 lb in.
(29.7-34.7 N·m)
Drain can (13) Left VIGV actuator Hand-tight (c)
rod-end port
Preformed packings Oil tube/hose (25) (b)
(11, 12), Drain can
(13)
Oil tube/hose (25) Reducer (8) Coupling nut 262-308 lb in.
(29.7-34.7 N·m)
Drain can (13) Left VIGV actuator Hand-tight (c)
head-end port
Oil tube/hose (26) Drain cans (13) Coupling nuts 262-308 lb in.
(two places) (29.7-34.7 N·m)
IGV oil tube (27) Oil tube/hoses Coupling nuts 262-308 lb in.
(15, 24) (29.7-34.7 N·m)
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Table 3. LPC Module Final Assembly (See figure 3.) (Continued)
Attach To Secure
Item Item With Torque Notes
Oil manifold (28) Oil tube/hoses Coupling nuts 262-308 lb in.
(16, 26) (29.7-34.7 N·m)
Oil manifold (29) Oil tube/hoses Coupling nuts 262-308 lb in.
(14, 25) (29.7-34.7 N·m)
Oil tube/hoses Angle bracket (17, Clamps (30), 57-67 lb in. (a)
(24, 25), figure 1) Bolts (18), (6.5-7.5 N·m)
Oil manifold (28) Washers (19)
IGV oil tube (27), Oil Angle brackets (14, Clamps (31), 57-67 lb in. (a)
manifolds (28, 29) 15, 16, figure 1) Bolts (18), (6.5-7.5 N·m)
Washers (19)
IGV oil tube (27), Oil IGV bracket (13, Clamps (32), 57-67 lb in. (a)
manifolds (28, 29) figure 1) Bolts (18), (6.5-7.5 N·m)
Washers (19)
IGV oil tube (27), Oil No. 1 electrical Clamps (33), 57-67 lb in. (a)
manifolds (28, 29) interface panel (5) Bolts (18), (6.5-7.5 N·m)
Washers (19)
IGV oil tube (27), Oil Angle bracket (11, Clamps (17), 57-67 lb in. (a)
manifolds (28, 29) figure 1) Bolts (18), (6.5-7.5 N·m)
Washers (19)
IGV oil tube (34) Oil manifold (29) Coupling nut 460-540 lb in.
(52.0-61.0 N·m)
IGV oil tube (35) IGV oil tube (27) Coupling nut 55-65 lb ft
(77-88 N·m)
Teflon hose (20) IGV oil tube (34) Coupling nut 460-540 lb in.
(52.0-61.0 N·m)
Teflon hose (20) Union (86, figure 3, Coupling nut 460-540 lb in.
SWP 1913 01) (52.0-61.0 N·m)
IGV oil hose (21) IGV oil tube (35) Coupling nut 55-65 lb ft
(77-88 N·m)
IGV oil hose (21) Union (84, figure 3, Coupling nut 55-65 lb ft
SWP 1913 01) (77-88 N·m)
IGV oil tube (34) No. 1 electrical Clamps (23), 57-67 lb in. (a)
interface panel (5) Bolts (2) (6.5-7.5 N·m)
Change 4 15
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Volume II GE Industrial AeroDerivative Gas Turbines
SWP 1913 04
Table 3. LPC Module Final Assembly (See figure 3.) (Continued)
Attach To Secure
Item Item With Torque Notes
IGV oil tube (35) No. 1 electrical Clamps (22), 57-67 lb in. (a)
interface panel (5) Bolts (2) (6.5-7.5 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
WARNING
Lubricating oil, MIL-L-7808, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(b) Lubricate preformed packing using lubricating oil.
(c) Align drain fittings before tightening.
Figure 4. Front Frame/HPC Flange Brackets
16 Change 4
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SWP 1913 04
Table 4. Front Frame/HPC Flange Brackets (See figure 4.)
Attach To Secure
Item Item With Torque Notes
VSV actuator Boltholes 18, 19, Bolts (2) 380-420 lb in.
bracket (1) 24, 26 (42.9-47.5 N·m) (a) (b)
Bolthole 25 Bolt (3) 209-231 lb in.
(23.7-26.0 N·m) (a) (b)
Bolthole 27 Bolt (4) 570-630 lb in.
(64.4-71.2 N·m) (a) (b)
Hydraulic Bolthole 33 Bolt (2) 380-420 lb in.
bracket (5) (42.9-47.5 N·m) (a) (b)
Bolthole 34 Bolt (4) 570-630 lb in.
(64.4-71.2 N·m) (a) (b)
Bracket Boltholes 45, 46 Bolts (2) 380-420 lb in.
assembly (6) (42.9-47.5 N·m) (a) (b)
Bracket Front frame Bolt (7) 61.8-68.3 lb in.
assembly (6) (7.0-7.7 N·m) (a) (b)
Bracket Bolthole 54 Bolt (2) 380-420 lb in.
assembly (8) (42.9-47.5 N·m) (a) (b)
Bolthole 55 Bolt (4) 570-630 lb in.
(64.4-71.2 N·m) (a) (b)
Bracket Front frame Bolt (7) 61.8-68.3 lb in.
assembly (8) (7.0-7.7 N·m) (a) (b)
VSV actuator Boltholes 60, 61, Bolts (2) 380-420 lb in.
bracket (9) 66, 68 (42.9-47.5 N·m) (a) (b)
Bolthole 67 Bolt (3) 209-231 lb in.
(23.7-26.0 N·m) (a) (b)
Bolthole 69 Bolt (4) 570-630 lb in.
(64.4-71.2 N·m) (a) (b)
NOTES:
(a) Lubricate threads and washer faces of bolt/nuts using thread lubricant.
(b) Safety-wire
Change 4 17
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SWP 1913 04
Figure 5. Core Module Final Assembly (Sheet 1 of 8)
18 Change 4
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SWP 1913 04
Figure 5. Core Module Final Assembly (Sheet 2 of 8)
Change 4 19
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Figure 5. Core Module Final Assembly (Sheet 3 of 8)
20 Change 4
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SWP 1913 04
Figure 5. Core Module Final Assembly (Sheet 4 of 8)
Change 4 21
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Figure 5. Core Module Final Assembly (Sheet 5 of 8)
22 Change 4
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Figure 5. Core Module Final Assembly (Sheet 6 of 8)
Change 4 23
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Figure 5. Core Module Final Assembly (Sheet 7 of 8)
24 Change 4
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Figure 5. Core Module Final Assembly (Sheet 8 of 8)
Change 4 25
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SWP 1913 04
Table 5. Core Module Final Assembly (See figure 5.)
Attach To Secure
Item Item With Torque Notes
Preformed B-sump air tube (2, (a)
packing (1) figure 6,
SWP 1913 02)
Gasket (2), Flange Air elbow (21, Bolts (4), Nuts (5) 61.8-68.3 lb in. (b) (c)
coupling (3) figure 5, (7.0-7.7 N·m)
SWP 1913 01)
B-sump air tube (2, Flange coupling (3) Coupling nut Hand-tight (d)
figure 6,
SWP 1913 02)
Gasket (6), Air Front frame Bolts (8) 61.8-68.3 lb in. (b)
manifold (7) (7.0-7.7 N·m)
Air manifold (7) B-sump bracket (3, Retaining strap (9), 570-630 lb in. (b)
figure 4, Bolts (8), (64.4-71.2 N·m)
SWP 1913 02) Washers (10),
Nuts (5)
Air manifold (7) Vent bracket (6, Clamp (11), Bolts 570-630 lb in. (b)
figure 4, (8) (64.4-71.2 N·m)
SWP 1913 02)
Air manifold (7) B-sump bracket (4, Clamp (12), Bolts 570-630 lb in. (b)
figure 4, (8), Washers (10), (64.4-71.2 N·m)
SWP 1913 02) Nuts (5)
Air manifold (7) B-sump bracket (9, Clamp (13), Bolts 570-630 lb in. (b)
figure 4, (8), Washers (10), (64.4-71.2 N·m)
SWP 1913 02) Nuts (5)
Air manifold (7) B-sump bracket (7, Clamp (14), Bolts 570-630 lb in. (b)
figure 4, (8) (64.4-71.2 N·m)
SWP 1913 02)
Gasket (15), Air Front frame Bolts (8) 61.8-68.3 lb in. (b)
manifold (7) (7.0-7.7 N·m)
Preformed packing Air tube (17) (a)
(16)
Gasket (65), Flange Air manifold (7) Bolts (19), Nuts (5) 570-630 lb in. (b) (c)
coupling (18) (64.4-71.2 N·m)
26 Change 4
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SWP 1913 04
Table 5. Core Module Final Assembly (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
Air tube (17) Flange coupling Coupling nut Hand-tight (d)
(18)
Gasket (66), B- and C-sump Bolts (4), Nuts (5) 570-630 lb in. (b)
Air tube (17) vent fitting (64.4-71.2 N·m)
Preformed packing Right VSV actuator 135-150 lb in. (b)
(20), Reducer (21) head-end port (15.3-16.9 N·m)
Preformed packing Right VSV actuator 135-150 lb in. (a)
(22), Reducer (23) rod-end port (15.3-16.9 N·m)
Preformed packing Left VSV actuator 135-150 lb in. (a)
(24), Reducer (25) head-end port (15.3-16.9 N·m)
Preformed packing Left VSV actuator 135-150 lb in. (a)
(26), Reducer (27) rod-end port (15.3-16.9 N·m)
Preformed packing Oil manifold (31) (a)
(28, 29), Drain can
(30)
Oil manifold (31) Reducers (21, 25) Coupling nuts 270-300 lb in.
(30.5-33.9 N·m)
Drain can (30) Left/right VSV Hand-tight (f)
actuator head-end
ports
Preformed packing Oil manifold (32) (a)
(28, 29), Drain can
(30)
Oil manifold (32) Reducers (23, 27) Coupling nuts 270-300 lb in.
(30.5-33.9 N·m)
Drain can (30) Left/right VSV Hand-tight (f)
actuator rod-end
ports
Oil manifold (33) Drain can (30) Coupling nuts 270-300 lb in.
(30.5-33.9 N·m)
Change 4 27
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SWP 1913 04
Table 5. Core Module Final Assembly (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
Oil manifold (33) Oil drain tube (51, Coupling nuts 270-300 lb in.
figure 5, (30.5-33.9 N·m)
SWP 1913 01)
Oil manifold (33) VBV bracket (6, Clamp (34), 55-70 lb in. (b)
figure 4, Bolt (8), (6.2-7.9 N·m)
SWP 1913 01) Washer (10),
Nut (5)
VSV oil tube (10, Oil manifold (32) Coupling nut 450-550- lb in.
figure 5, (50.8-62.1 N·m)
SWP 1913 01)
VSV oil tube (11, Oil manifold (31) Coupling nut 650-770 lb in.
figure 5, (73.4-87.0 N·m)
SWP 1913 01)
Oil manifold (35) Drain can (30) Coupling nut 270-300 lb in.
(30.5-33.9 N·m)
Oil drain tube (39, Drain can (30) Coupling nut 270-300 lb in.
figure 5, (30.5-33.9 N·m)
SWP 1913 01)
Oil drain tube (39, Oil manifold (35) Coupling nut 270-300 lb in.
figure 5, (30.5-33.9 N·m)
SWP 1913 01)
Oil manifold (36) Oil manifold (23, Coupling nut 650-770 lb in.
figure 5, (73.4-87.0 N·m)
SWP 1913 01)
Oil manifold (36) Oil manifold (45, Coupling nut 650-770 lb in.
figure 5, (73.4-87.0 N·m)
SWP 1913 01)
Oil manifold (37) Oil manifold (26, Coupling nut 650-770 lb in.
figure 5, (73.4-87.0 N·m)
SWP 1913 01)
Oil manifold (37) Oil manifold (43, Coupling nut 650-770 lb in.
figure 5, (73.4-87.0 N·m)
SWP 1913 01)
28 Change 4
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SWP 1913 04
Table 5. Core Module Final Assembly (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
VBV oil tube (38) Lower left VBV Coupling nut 270-300 lb in.
actuator drain can (30.5-33.9 N·m)
(34, figure 5,
SWP 1913 01)
VBV oil tube (38) Oil manifold (35) Coupling nut 270-300 lb in.
(30.5-33.9 N·m)
Oil tube (52, figure Oil manifold (36) Coupling nut 270-300 lb in.
5, SWP 1913 01) (30.5-33.9 N·m)
Oil tube Oil manifold (37) Coupling nut 270-300 lb in.
(53, figure 5, (30.5-33.9 N·m)
SWP 1913 01)
VBV oil tube (39) Lower right VBV Coupling nut 270-300 lb in.
actuator drain can (30.5-33.9 N·m)
(34, figure 5,
SWP 1913 01)
VBV oil tube (39) Oil manifold (35) Coupling nut 270-300 lb in.
(30.5-33.9 N·m)
Oil tube Oil manifold (36) Coupling nut 270-300 lb in.
(55, figure 5, (30.5-33.9 N·m)
SWP 1913 01)
Oil tube Oil manifold (37) Coupling nut 270-300 lb in.
(54, figure 5, (30.5-33.9 N·m)
SWP 1913 01)
VBV oil tube (9, Oil manifold (37) Coupling nut 75-91 lb in.
figure 5, (102-123 N·m)
SWP 1913 01)
VBV oil tube (12, Oil manifold (36) Coupling nut 75-91 lb in.
figure 5, (102-123 N·m)
SWP 1913 01)
Supply oil Front frame Coupling nut 135-150 lb in.
tube (40) (15.3-16.9 N·m)
Oil manifold (41) Union (54, figure 3, Coupling nut 270-300 lb in.
SWP 1913 01) (30.5-33.9 N·m)
Change 4 29
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SWP 1913 04
Table 5. Core Module Final Assembly (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
Oil manifold (41) Front frame Coupling nut 450-550 lb in.
(50.8-62.1 N·m)
Oil manifold (41) Oil bracket (11, Clamp (42), 61.8-68.3 lb in. (b)
figure 4, Bolt (8) (7.0-7.7 N·m)
SWP 1913 01)
Oil manifold (41) No. 2 electrical Clamps (43), 61.8-68.3 lb in. (b)
interface panel (12, Bolt (8) (7.0-7.7 N·m)
figure 4,
SWP 1913 01)
Oil manifold (31, Bracket assembly Clamp (44, 45, 46), 61.8-68.3 lb in. (b)
32, 35, 37, 36, 41) (8, figure 4) Spacer (47), Bolt (7.0-7.7 N·m)
(48, 49), Washer
(50)
Oil manifold (31, Bracket assembly Clamp (51, 52, 53), 61.8-68.3 lb in. (b)
32, 35, 37, 36, 41) (6, figure 4) Spacer (54), Bolt (7.0-7.7 N·m)
(49, 55), Washer
(50)
Oil manifold (31, Front frame (two Clamp (56, 57), 61.8-68.3 lb in. (b)
32, 37, 36) places) Spacer (58), Bolt (7.0-7.7 N·m)
(59), Washer (60)
Tubes (31, 32) Front frame Clamp (61), Spacer 61.8-68.3 lb in. (b)
(62), Bolt (63), (7.0-7.7 N·m)
Washer (60)
Oil manifold (35) Hydraulic Clamp (64), Bolt 61.8-68.3 lb in. (b)
bracket (5, figure 4) (8) (7.0-7.7 N·m)
30 Change 4
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
SWP 1913 04
Table 5. Core Module Final Assembly (See figure 5.) (Continued)
Attach To Secure
Item Item With Torque Notes
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust venti-
lation - if not available, use an approved respirator.
NOTES:
(a) Lubricate packings using lubricating oil.
(b) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(c) Boltheads face aft.
(d) Use cushion jaw pliers, if necessary.
(e) Safety-wire.
(f) Align drain fittings before tightening.
Figure 6. HPT/LPT Flange Brackets (Sheet 1 of 2)
Change 4 31
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SWP 1913 04
Figure 6. HPT/LPT Flange Brackets (Sheet 2 of 2)
Table 6. HPT/LPT Flange Brackets (See figure 6.)
Attach To Secure
Item Item With Torque Notes
HP recoup Bolthole 135, Bolt (2), Nuts (3) 210-230 lb in. (a) (b)
bracket (1) 136, 1 (23.7-25.9 N·m)
Bracket (4) Bolthole 73, 74, 75 Bolts (2), Nuts (3) 210-230 lb in. (a) (b)
(23.7-25.9 N·m)
LPT cooling air Bolthole 27, 28, 29 Bolts (2), Nuts (3) 210-230 lb in. (a) (b)
support bracket (5) (23.7-25.9 N·m)
LPT cooling air LPT cooling air Bolts (7), Nuts (8) Finger-tight 55-70 (a)
support bracket (6) support bracket (5) lb in. (6.2-7.9 N·m)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(b) Boltheads face aft.
32 Change 4
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SWP 1913 04
12. LPT Module Final Assembly.
See figure 7 and table 7.
7
13. Engine Assembly Electrical Harnesses Installation.
See figure 8 and table 8.
8
Change 4 33
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Figure 7. LPT Module Final Assembly (Sheet 1 of 4)
34 Change 4
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Figure 7. LPT Module Final Assembly (Sheet 2 of 4)
Change 4 35
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Figure 7. LPT Module Final Assembly (Sheet 3 of 4)
36 Change 4
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Figure 7. LPT Module Final Assembly (Sheet 4 of 4)
Change 4 37
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Table 7. LPT Module Final Assembly (See figure 7.)
Attach To Secure
Item Item With Torque Notes
Bracket (1) Tray mount Bolts (2) 55-70 lb in. (a)
bracket (6.2-7.9 N·m)
(31, figure 1,
SWP 1913 02)
Bracket (1) Bracket (TBP) Bolts (2) 55-70 lb in. (a)
(6.2-7.9 N·m)
Gasket (3), Lube and scavenge Bolts (5) 61.8-68.3 lb in. (a)
Scavenge oil pump (7.0-7.7 N·m)
tube (4)
Gasket (6), B scavenge oil tube Bolts (7), Nuts (8) 61.8-68.3 lb in. (a)
Scavenge oil (54, figure 6, (7.0-7.7 N·m)
tube (4) SWP 1913 02)
Scavenge oil Bracket (1) Clamp (9), 55-70 lb in. (a)
tube (4) Bolt (2) (6.2-7.9 N·m)
Scavenge oil Bracket (1) Clamp (10), Spacer 55-70 lb in. (a)
tube (4) (11), Bolt (12) (6.2-7.9 N·m)
Gasket (13), Lube and scavenge Bolts (5) 55-70 lb in. (a)
Scavenge oil pump (6.2-7.9 N·m)
tube (14), Electrical
bracket (15)
Scavenge oil Bracket (1) Clamp (17), 55-70 lb in. (a)
tube (14) Bolt (2) (6.2-7.9 N·m)
Gasket (16), C Scavenge oil Bolt (7), Nut (8) 55-70 lb in. (a)
Scavenge oil tube (48, figure 6, (6.2-7.9 N·m)
tube (14) SWP 1913 02)
Teflon hose (18) Oil supply tube Coupling nut 650-770 lb in.
(23) (73.4-87.0 N·m)
Teflon hose (18) B and C supply oil Coupling nut 650-770 lb in.
tube (44, figure 6, (73.4-87.0 N·m)
SWP 1913 02)
Teflon hose (20) E-sump scavenge Coupling nut 650-770 lb in.
manifold fitting (73.4-87.0 N·m)
38 Change 4
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SWP 1913 04
Table 7. LPT Module Final Assembly (See figure 7.) (Continued)
Attach To Secure
Item Item With Torque Notes
Teflon hose (21) D-sump scavenge Coupling nut 650-770 lb in.
manifold fitting (73.4-87.0 N·m)
Teflon hose (22) Oil supply Coupling nut 75-91 lb ft
manifold fitting (102-123 N·m)
Oil supply tube (23) Teflon hose (22) Coupling nut 75-91 lb ft
(102-123 N·m)
Oil supply tube (23) Teflon hose (24) Coupling nut 75-91 lb ft
(102-123 N·m)
Teflon hose (20) Oil supply Clamp (25), 55-70 lb in. (a)
bracket (21, Bolt (26) (6.2-7.9 N·m)
figure 3,
SWP 1913 03)
Teflon hose (20) Bracket (1) Clamp (25), 55-70 lb in. (a)
(2 places) Bolt (26) (6.2-7.9 N·m)
Teflon hose (20) Fitting Coupling nut 75-91 lb ft
(102-123 N·m)
Teflon hose (20) Oil scavenge Clamp (29), 55-70 lb in. (a)
bracket (12, Bolt (26) (6.2-7.9 N·m)
figure 1,
SWP 1913 03)
(2 places)
Teflon hose (20) Lube supply Clamp (29), 55-70 lb in. (a)
bracket (13, Bolt (26) (6.2-7.9 N·m)
figure 1,
SWP 1913 03)
Teflon hose (21) Oil supply Clamp (27), 55-70 lb in. (a)
bracket (21, Bolt (26) (6.2-7.9 N·m)
figure 3,
SWP 1913 03)
Teflon hose (21) Bracket (1) Clamp (27), 55-70 lb in. (a)
(2 places) Bolt (26) (6.2-7.9 N·m)
Teflon hose (21) Fitting Coupling nut 75-91 lb ft
(102-123 N·m)
Change 4 39
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SWP 1913 04
Table 7. LPT Module Final Assembly (See figure 7.) (Continued)
Attach To Secure
Item Item With Torque Notes
Teflon hose (24) Electrical Bracket Clamp (28), 55-70 lb in. (a)
(16, figure 1, Bolt (26) (6.2-7.9 N·m)
SWP 1913 03)
(2 places)
Teflon hose (24) Oil supply Clamp (28), 55-70 lb in. (a)
bracket (21, Bolt (26) (6.2-7.9 N·m)
figure 3,
SWP 1913 03)
Teflon hose (24) Bracket (1) Clamp (28), 55-70 lb in. (a)
Bolt (26) (6.2-7.9 N·m)
Oil supply tube (23) Bracket (1) Clamp (30), 55-70 lb in. (a)
(2 places) Bolt (26) (6.2-7.9 N·m)
Oil supply tube (23) Bracket (1) Clamp (31), 55-70 lb in. (a)
Bolt (26) (6.2-7.9 N·m)
Gasket (32), HP air LPT case Bolts (34) 55-70 lb in. (a) (b)
tube (37) (6.2-7.9 N·m)
Gasket (35), LPT case Bolts (34) 55-70 lb in. (a) (b)
Tee (36) (6.2-7.9 N·m)
HP air tube (37) Tee (36) Coupling nut 40-50 lb ft (b)
(54.2-67.8 N·m)
HP air tube (37) Recoup bracket (1, Retaining 55-70 lb in. (a)
figure 6) strap (38), (6.2-7.9 N·m)
Bolts (2),
Washers (39),
Nuts (8)
Gasket (40), HP air LPT case Bolts (34) 55-70 lb in. (a) (b)
tube (44) (6.2-7.9 N·m)
Gasket (42), LPT case Bolts (34) 55-70 lb in. (a) (b)
Elbow (43) (6.2-7.9 N·m)
HP air tube (44) Tee (43) Coupling nut 40-50 lb ft (b)
(54.2-67.8 N·m)
40 Change 4
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SWP 1913 04
Table 7. LPT Module Final Assembly (See figure 7.) (Continued)
Attach To Secure
Item Item With Torque Notes
HP air tube (44) Bracket (4, Retaining 55-70 lb in. (a)
figure 6) strap (45), (6.2-7.9 N·m)
Bolts (2),
Washers (39),
Nuts (8)
HP recoup air tube Tee (36) Coupling nut 40-50 lb ft (b)
(24, figure 6, (54.2-67.8 N·m)
SWP 1913 02)
HP recoup air tube Tee (43) Coupling nut 40-50 lb ft (b)
(42, figure 6, (54.2-67.8 N·m)
SWP 1913 02)
LPT air tube (15, Air manifold (1, Coupling nut 40-50 lb ft (a)
figure 6, SWP 1913 figure 2, (54.2-67.8 N·m)
02) SWP 1913 03)
LPT air tube (59, Air manifold (2, Coupling nut 40-50 lb ft (a)
figure 6, SWP 1913 figure 2, (54.2-67.8 N·m)
02) SWP 1913 03)
NOTES:
(a) Lubricate threads and washer faces of bolts/nuts using thread lubricant.
(b) Safety-wire.
Change 4 41
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Figure 8. Engine Assembly Electrical Harnesses (Sheet 1 of 5)
42 Change 4
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SWP 1913 04
Figure 8. Engine Assembly Electrical Harnesses (Sheet 2 of 5)
Change 4 43
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Figure 8. Engine Assembly Electrical Harnesses (Sheet 3 of 5)
44 Change 4
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Figure 8. Engine Assembly Electrical Harnesses (Sheet 4 of 5)
Change 4 45
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Figure 8. Engine Assembly Electrical Harnesses (Sheet 5 of 5)
46 Change 4
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Table 8. Engine Assembly Electrical Harnesses (See figure 8.)
Attach To Secure
Item Item With Torque Notes
T2 sensor electrical Electrical bracket Spring clip (a)
lead (1) (23, figure 1)
Electrical bracket Spring clip (a)
(22, figure 1)
Electrical bracket Spring clip (a)
(19, figure 1)
Angle bracket Spring clip (a)
(18, figure 1)
Angle bracket Spring clip (a)
(17, figure 1)
Angle bracket Spring clip (a)
(16, figure 1)
Angle bracket Spring clip (a)
(15, figure 1)
Angle bracket Spring clip (a)
(14, figure 1)
IGV bracket Spring clip (a)
(13, figure 1)
Channel bracket Spring clip (a)
(1, figure 3)
No. 1 electrical Jamnut Hand-tight, then (b)
interface panel 1/4 turn
(5, figure 3)
Left side VIGV/ Left VIGV actuator Connector ring Hand-tight
LVDT electrical
harness (2)
Angle bracket Spring clip (a)
(18, figure 1)
Angle bracket Spring clip (a)
(17, figure 1)
Change 4 47
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Table 8. Engine Assembly Electrical Harnesses (See figure 8.) (Continued)
Attach To Secure
Item Item With Torque Notes
Angle bracket Spring clip (a)
(16, figure 1)
Angle bracket Spring clip (a)
(15, figure 1)
Angle bracket (14, Spring clip (a)
figure 1)
Channel bracket Spring clip (a)
(1, figure 3)
No. 1 electrical Jamnut Hand-tight, then (b)
interface panel 1/4 turn
(5, figure 3)
Right side VIGV/ Right VIGV Connector ring Hand-tight
LVDT electrical actuator
harness (3)
Angle bracket Clamp (5), Bolt (6) 55-70 lb in. (c)
(11, figure 1) (6.2-7.9 N·m)
Channel bracket Clamp (5), Bolt (6) 55-70 lb in. (a) (c)
(1, figure 3) (6.2-7.9 N·m)
No. 1 electrical Jamnut Hand-tight, then (b)
interface panel 1/4 turn
(5,figure 3)
HCU torque motor HCU VSV torque Connector ring Hand-tight
electrical motor connector
harness (4) (bottom)
HCU VSV torque Connector ring Hand-tight
motor connector
(middle)
HCU VSV torque Connector ring Hand-tight
motor connector
(top)
48 Change 4
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Table 8. Engine Assembly Electrical Harnesses (See figure 8.) (Continued)
Attach To Secure
Item Item With Torque Notes
No. 1 electrical Jamnut Hand-tight, then (b)
interface panel 1/4 turn
(5, figure 3)
Left side Left VSV actuator Connector ring Hand-tight
VBV/VSV/LVDT
electrical harness
(2, figure 6,
SWP 1913 01)
Right side Right VSV actuator Connector ring Hand-tight
VBV/VSV/LVDT
electrical harness
(8, figure 6,
SWP 1913 01)
T3 sensor electrical HP recoup bracket Clamp (8), Bolt (9) 55-70 lb in. (c)
lead (7) (15, figure 3, (6.2-7.9 N·m)
SWP 1913 02)
Left side UV UV detector Bolt (35) 55-70 lb in.
detector integral brackets (16 and (6.2-7.9 N·m)
lead (10), Cooling 17, figure 3,
can (33), SWP 1913 02)
Gasket (34)
Left side UV HP recoup bracket Clamp (11) 55-70 lb in. (a) (d)
detector integral (15, figure 3, (6.2-7.9 N·m)
lead (10) SWP 1913 02)
Leads (7, 10) Electrical bracket Clamps (11, 12), 55-70 lb in. (a) (c)
(1, figure 3, Bolt (9) (6.2-7.9 N·m)
SWP 1913 02)
T3 sensor electrical UV detector Clamp (13), 55-70 lb in. (a) (c)
lead (7) bracket (3, figure 3, Bolt (9) (6.2-7.9 N·m)
SWP 1913 02)
Left side UV UV detector Clamp (14), 55-70 lb in. (a) (c)
detector integral bracket (3, figure 3, Bolt (9), Washer (6.2-7.9 N·m)
lead (10) SWP 1913 02) (15), Nut (16)
Change 4 49
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Table 8. Engine Assembly Electrical Harnesses (See figure 8.) (Continued)
Attach To Secure
Item Item With Torque Notes
Leads (7, 10) Electrical bracket Clamp (17, 18), 55-70 lb in. (a) (c)
(4, figure 3, Bolt (9) (6.2-7.9 N·m)
SWP 1913 02)
Right side UV UV detector Bolts (35) 55-70 lb in.
detector integral bracket (3, figure 3, (6.2-7.9 N·m)
lead (19), Cooling SWP 1913 02)
can (33),
Gasket (34)
Right side UV Electrical bracket Clamp (20), 55-70 lb in. (a) (c)
detector integral (4, figure 3, Bolt (9) (6.2-7.9 N·m)
lead (19) SWP 1913 02)
Leads (7, 10) Cooling bracket (5, Clamp (21, 22), 55-70 lb in. (a) (c)
figure 3, SWP 1913 Bolt (9) (6.2-7.9 N·m)
02)
Right side UV Cooling bracket Clamp (23), 55-70 lb in. (a) (c)
detector integral (5, figure 3, Bolts (9) (6.2-7.9 N·m)
lead (19) SWP 1913 02)
Leads (10, 19) Cooling bracket Clamp (24, 25), 55-70 lb in. (a) (c)
(6, figure 3, Bolt (9) (6.2-7.9 N·m)
SWP 1913 02)
T3 sensor electrical Cooling bracket Clamp (26), 55-70 lb in. (a) (c)
lead (7) (6, figure 3, Bolt (9) (6.2-7.9 N·m)
SWP 1913 02)
Leads (7, 19) Electrical bracket Clamp (27, 28), 55-70 lb in. (a) (c)
(22, figure 1, Bolt (9) (6.2-7.9 N·m)
SWP 1913 02)
Left side UV Electrical bracket Clamp (29), 55-70 lb in. (a) (c)
detector integral (22, figure 1, Bolt (9) (6.2-7.9 N·m)
lead (10) SWP 1913 02)
Right side UV Bridge bracket Clamp (31), 55-70 lb in. (a) (c) (e)
detector integral (17, figure 4, Bolt (9) (6.2-7.9 N·m)
lead (19) SWP 1913 02)
50 Change 4
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Table 8. Engine Assembly Electrical Harnesses (See figure 8.) (Continued)
Attach To Secure
Item Item With Torque Notes
Left side UV Bridge bracket Clamp (30), 55-70 lb in. (a) (c) (e)
detector integral (17, figure 4, Bolt (9) (6.2-7.9 N·m)
lead (10) SWP 1913 02)
T3 sensor integral Bridge bracket Clamp (32), 55-70 lb in. (a) (c)
lead (7) (17, figure 4, Bolt (9) (6.2-7.9 N·m)
SWP 1913 02)
T3 sensor integral No. 3 electrical Jamnut Hand-tight, then (b)
lead (7) interface panel 1/4 turn
(20, figure 4,
SWP 1913 02)
NOTES:
(a) Lead may be spiral wrapped using silicone tape in the area of spring clips or clamps and
0.5 inch (12.7 mm) on either side of clip or clamp to provide positive lead clamping as
required.
(b) Safety-wire to adjacent jamnut using R297P02 safety wire.
(c) Lubricate threads and washer faces of bolts using thread lubricate.
(d) See figure 3, SWP 1913 02 for attaching hardware.
(e) See packager's manual for UV detector integral lead final hookup.
51/(52 Blank)
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WP 1914 00
WORK PACKAGE
TECHNICAL PROCEDURES
FLOW DIVIDER VALVE REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-6 ...... 0
Alphabetical Index
Subject Page
Fuel Pressurization Valve Removal ............................................................................................ 3
Fuel Pressurization Valve Installation......................................................................................... 4
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WP 1914 00
1. Introduction.
This work package (WP) contains instructions for removing and installing fuel pressurization
valve. (Reference kit, PN 682L241.)
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Petrolatum Fed Spec VV-P-236
Safety Wire (0.032 inch) R297P04
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal J219P05 1
Gasket Seal J219P07 1
Packing, Preformed J221P904 1
Packing, Preformed J221P910 2
Packing, Preformed J221P912 3
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WP 1914 00
6. Fuel Pressurization Valve Removal.
A. Position waste fluid container under fuel pressurization valve (1, figure 1).
WARNING
• Fuel in liquid, vapor, or mist form is flammable, irritating to
the skin and respiratory tract, and poisonous in the digestive
tract. Remove saturated clothing, wash skin well, don't swal-
low liquid, and don't breathe mist or vapor.
• Fuel system is pressurized. Use care to prevent injury when
disconnecting lines.
B. Remove drain plug (27) from pressurization valve (1). Drain fuel into container.
Reinstall drain plug.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
C. Remove safety wire. Disconnect water inlet line (2) from tube nipple (3). Remove
nipple and preformed packing (4) from mixing tee (5). Discard preformed packing.
D. Remove four bolts and washers (7) connecting fuel/water outlet line (6) to mixing
tee(5).
E. Remove seal gasket (8). Discard seal gasket.
F. Remove safety wire. Remove mixing tee (5) from customer-supplied mixing line (9).
G. Remove safety wire. Disconnect customer-supplied mixing line (9) from tube
nipple (10).
H. Remove safety wire. Remove nipple (10) from check valve (11). Remove preformed
packing (12) from nipple. Discard preformed packing.
I. Remove safety wire. Remove check valve (11) from pressurization valve (1).
Remove preformed packing (13) from check valve. Discard preformed packing.
J. Remove safety wire. Disconnect reference pressure line (14) from tube elbow (15).
K. Remove safety wire. Loosen hex nut (16) at pressurization valve (1). Remove elbow
(15), nut, and preformed packing (17) from pressurization valve (1). Discard
preformed packing.
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L. Remove safety wire. Disconnect fuel line (19) from tube nipple (18). Remove nipple
from check valve (20). Remove preformed packing (21) from nipple. Discard
preformed packing.
M. Remove safety wire. Remove check valve (20) from customer-supplied interface (22).
Remove preformed packing (23) from check valve. Discard preformed packing.
N. Remove four bolts (24) and washers (25) that secure customer-supplied interface (22)
to pressurization valve (1). Remove valve and remove seal gasket (26). Discard seal
gasket.
7. Fuel Pressurization Valve Installation.
A. Install new seal gasket (26) onto pressurization valve (1). Secure pressurization valve
tocustomer-supplied interface (22) using four washers (25) and bolts (24). Tighten
bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
B. Lubricate new preformed packing (23) with petrolatum. Install preformed packing
onto check valve (20). Install check valve into customer-supplied interface (22),
tighten to270-300 lb in. (30.5-33.9 N·m) of torque, and safety-wire.
C. Lubricate new preformed packing (21) with petrolatum. Install preformed packing
onto tube nipple (18). Install tube nipple onto check valve (20), tighten to
270-300 lb in.(30.5-33.9 N·m) of torque, and safety-wire.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
D. Connect fuel line (19) from primary nozzle manifold to nipple (18). Tighten coupling
nut to 650-700 lb in. (73.4-79.1 N·m) of torque and safety-wire.
E. Lubricate new preformed packing (17) with petrolatum. Install nut (16) onto elbow
(15). Install preformed packing onto elbow and install elbow into pressurization valve
(1). Tighten nut to 135-150 lb in. (15.3-16.9 N·m) of torque and safety-wire.
F. Connect elbow (15) to reference pressure line (14) coupling nut to elbow (15), tighten
nut to 135-150 lb in. (15.3-16.9 N·m) of torque, and safety-wire.
G. Lubricate new preformed packing (13) with petrolatum. Install preformed packing
onto check valve (11). Install check valve into pressurization valve (1), tighten to
360-400 lb in. (40.7-45.2 N·m) of torque, and safety-wire.
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WP 1914 00
Figure 1. Fuel Pressurization
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H. Lubricate new preformed packing (12) with petrolatum. Install preformed packing
onto tube nipple (10). Install nipple onto check valve (11), tighten to 360-400 lb in.
(40.7-45.2 N·m) of torque, and safety-wire.
I. Connect customer-supplied mixing line (9) to mixing tee (5). Tighten coupling nut to
900-1100 lb in. (101.7-124.3 N·m) of torque and safety-wire.
J. Connect customer-supplied mixing line (9) onto nipple (10). Tighten coupling nut to
900-1100 lb in. (101.7-124.3 N·m) of torque and safety-wire.
K. Install new seal gasket (8) onto mixing tee (5). Install fuel/water outlet line (6) onto
gasket and mixing tee and secure with four bolts and washers (7). Tighten bolts to
55-70 lb in.(6.2-7.9 N·m) of torque.
L. Lubricate new preformed packing (4) with petrolatum. Install preformed packing onto
tube nipple (3). Install nipple into mixing tee (5). Tighten nipple to 540-600 lb in.
(61.0-67.8 N·m) of torque. Connect water inlet line (2) onto nipple. Tighten coupling
nut to 900-1100 lb in. (101.7-124.3 N·m) of torque and safety-wire.
NOTE
To achieve acceptable operation of the liquid fuel system, the primary
fuel manifold pressure must be set to 375-425 psig (2586-2930 kPa
gage) at sync idle. The pressure is set by adjusting two fixed orifices
which function as a pressure divider between the high and low pressure
lines.
M. Adjust primary fuel manifold pressure to 375-425 psig (2586-2930 kPa gage) by
changing downstream pressurizing valve orifice size as necessary. Refer to packager’s
instructions and fuel system drawings for location and replacement of pressurizing
valve orifice plates.
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WP 1916 00
6WP 1916 00
WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR WATER INJECTION
(SPRINT®) KIT REMOVAL AND INSTALLATION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 30
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 29 ...... 0
30 Blank . . . . . . 0
Alphabetical Index
Subject Page
High Pressure Compressor Water Injection (SPRINT®) Kit Installation .................................. 14
High Pressure Compressor Water Injection (SPRINT®) Kit Removal ...................................... 3
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WP 1916 00
1. Introduction.
This work package contains instructions for removing and installing the high pressure|
compressor water injection (SPRINT®) kit. The removal procedure will restore the gas turbine
to the original configuration. The installation procedure can only be used on a gas turbine that
is SPRINT® ready.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Grinding Die Pneumatic Grinder AR
4. Consumable Material.
Nomenclature Specification
Epoxy Paint MIL-C-22750, Color
26307
Molybdenum MIL-L-25681
Disulfide Royco 81MS
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GP460
Zinc Chromate Primer Fed. Spec.
TT-P-1757
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket 9608M08G48 2
Metal Seal Ring J1128P12 1
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WP 1916 00
6. High Pressure Compressor Water Injection (SPRINT®) Kit Removal.
NOTE
• This procedure applies to only six configurations of the SPRINT®
kit. The six kits covered are PN 682L294G07, PN 682L294G12,
PN 682L874G01, PN 682L903G01, PN 682L903G06, and PN
682L908G01. These instructions apply to all six configurations
of the SPRINT® kit listed above unless otherwise indicated.
• Steps A. and B. only required if removing SPRINT® kit,
PN 682L294G12, PN 682L874G01, PN 682L903G01, PN
682L903G06, and PN 682L908G01.
A. Remove SPRINT® kit air manifold from engine as follows:
(1) Support air manifold as needed. Remove coupling clamp (1, figure 1). Remove
bolts (18), gaskets (17), and plate orifice (16). Remove metal seal ring (2) from
stage 8 adapter (3). Discard gaskets and metal seal ring.
(2) Remove self-locking nuts (20) and bolts (19) that secure air tube (14) to air tube
or air manifold (4).
(3) Remove self-locking nuts (9) and bolts (8) that secure retaining strap (7) to
bracket (15). Remove restraining strap and air tube (14). Remove and discard
gasket (17).
NOTE
If removing SPRINT® kit PN 682L294G12, air tube will be removed
in substep (4). If removing SPRINT® with LPC spray injection kit,
PN 682L874G01, PN 682L903G01, PN 682L903G06, and PN
682L908G01, air manifold will be removed in substep (4).
(4) Remove self-locking nuts (13) and bolts (12) that secure air tube or air manifold
(4) to air manifold (10).
(5) Remove self-locking nuts (9) and bolts (8) that secure retaining strap (7)
to brackets (5 and 6). Remove restraining strap and air tube or air manifold (4).
Remove and discard gasket (11).
B. Remove air tube and air manifold brackets from engine as follows:
(1) Remove self-locking nuts (1, figure 2) and bolts (2) that secure brackets (3) to air
collector. Remove brackets (3).
(2) Remove bolts (6) and brackets (4 and 5).
3
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1
Figure 1. Air Tube/Manifold Installation
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2
Figure 2. Air Tube/Manifold Brackets
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C. Remove stage 8 bleed adapter (3, figure 1). Retain coupling clamp (1) for reuse, and
discard metal seal ring (2).
D. Remove bolts and flat washers that secure air collector access panels (figure 3).
Remove access panels.
3
E. Disconnect air tubes (2 and 3, figure 4) from air manifold.
4
F. On original configuration, remove self-locking nuts (8, figure 5), bolts (7), and gasket
(6) from air manifolds at 12:00 o'clock and 6:00 o'clock positions. Discard gaskets.
F.A.On current configuration, remove self-locking nuts (8), bolts (7) and gaskets (6) from
air manifold at 3:00 o'clock and 9:00 o'clock positions.
G. Remove self-locking nuts (2) that secure air manifold U-bolts (1) to brackets (4).
5
H. Remove air manifold U-bolts (1).
I. On original configuration, remove left side air manifold (5) and right side air manifold
(3).
I.A.On current configuration, remove top air manifold (9) and bottom air manifold (10).
J. Remove air tubes (2 and 3, figure 4) from water nozzles.
K. Disconnect water tubes (1) from water manifolds (figure 6).
L. Remove water tubes (1, figure 4) from water nozzles (2 and 3, figure 7).
NOTE
Steps M and O apply to kits PN 682L294G07, PN 682L294G12, PN
682L874G01, PN 682L903G01, and PN 682L908G01. Steps M.A.
and O.A. apply to kit PN 682L903G06.
M. Disconnect top water manifold (1, figure 6) from bottom water manifold (5) at
3:00 o'clock and 9:00 o'clock positions.
M.A.Disconnect top water manifold (1) from bottom water manifold (5) at 9:00 o'clock
position. Disconnect middle water manifold (6) from top and bottom water manifolds
(1 and 5) at 3:00 o'clock position.
N. Remove self-locking nuts that secure water manifold retaining straps (3) to
brackets (2). Remove straps.
6
O. Remove top and bottom water manifolds (1 and 5).
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Figure 3. Air Collector Access Panels
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Figure 4. Water Tubes and Air Tubes
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Figure 5. Air Manifold Removal and Installation
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Figure 6. Water Manifold Removal and Installation (Sheet 1 of 2)
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Figure 6. Water Manifold Removal and Installation (Sheet 2 of 2)
O.A. Remove top, bottom, and middle water manifolds (1, 5, and 6).
CAUTION
Ensure variable bypass valves (VBV) are in closed position so
hardware or tools will not fall into front frame.
NOTE
Original configuration water nozzle bolts are double hex head with safety wire or cable.
Current bolts are hex head without safety wire. Double hex head bolts will not be reinstalled.
P. Remove safety cable and bolts (4, figure 7) that secure short and long water nozzles
(2 and 3) to front frame.
Q. Remove short and long water nozzles (2 and 3) from front frame.
R. If SPRINT® kit with LPC injection, PN 682L874G01, PN 682L903G01, or
PN 682L903G06, is installed, remove water nozzles along with air and water tubing
and attaching hardware on inlet section, per packager’s instructions.
11
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S. Install 24 plugs (1, figure 7) into front frame and secure with bolts (4). Tighten bolts to
55-70 lb in. (6.2-7.9 N·m) of torque.
7
T. Install cover plates (7, figure 8) using bolts (8). Tighten bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
CAUTION
Do not remove more than three brackets at a time, or serious
engine damage could result. Install doublers, bolts, and nuts
in place of removed bracket(s) before removing next set of
brackets.
U. Remove brackets and install doublers onto LPC stator aft flange as follows (figure 9):
(1) Remove bolts, nuts, and three brackets at boltholes No. 2-5, 8-11, and 15-18.
(2) Remove remaining bolts, washers, and nuts at boltholes No. 1-23.
WARNING
Zinc Chromate Primer, TT-P-1757, is highly toxic to skin,
eyes, and respiratory tract. Skin and eye protection, and
vapor control are required. Avoid all contact.
(3) Apply zinc chromate primer onto shank and bearing surface of 96 bolts that secure
aft flange. Allow primer to dry.
(4) Apply thread lubricant onto threads and bearing surfaces of aft flange bolts.
(5) Install bolts, two long doublers, and nuts in aft flange, boltheads aft, doublers on
forward side of aft flange, at boltholes No. 4-23.
(6) Tighten aft flange nuts to 135-145 lb in. (15.2-16.3 N·m) of torque.
(7) Remove bolts, nuts, and two brackets at boltholes No. 24-32.
(8) Install bolts, one short doubler, and nuts in aft flange, boltheads aft, doublers on
forward side of aft flange at boltholes No. 24-31.
(9) Tighten aft flange nuts to 135-145 lb in. (15.2-16.3 N·m) of torque.
(10) Remove bolts, nuts, and three brackets at boltholes No. 34-37, 41-44, and 49-52.
(11) Remove remaining bolts, washers and nuts at boltholes No. 33-55.
12
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Figure 7. Water Nozzles
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(12) Install bolts, two long doublers, and nuts in aft flange, boltheads aft, doublers on
forward side of aft flange at boltholes No. 32-51.
9
8
(13) Tighten aft flange nuts to 135-145 lb in. (15.2-16.3 N·m) of torque.
(14) Remove bolts, nuts, and three brackets at boltholes No. 56-59, 61-64, and 66-69.
(15) Remove remaining bolts, washers, and nuts at boltholes No. 60-71.
(16) Install bolts, two long doublers, and nuts in aft flange, boltheads aft, doublers on
forward side of aft flange at boltholes No. 52-71.
(17) Tighten aft flange nuts to 135-145 lb in. (15.2-16.3 N·m) of torque.
(18) Remove bolts, nuts and one bracket at boltholes No. 72-76.
(19) Remove remaining bolts, washers, and nuts at boltholes No. 77-81.
(20) Install bolts, one short doubler, and nuts in aft flange, boltheads aft, doublers on
forward side of aft flange at boltholes No. 72-79.
(21) Tighten aft flange nuts to 135-145 lb in. (15.2-16.3 N·m) of torque.
(22) Remove bolts, nuts, and two brackets at boltholes No. 82-85 and No. 89-92.
(23) Remove remaining bolts, washers, and nuts at boltholes No. 86-96.
(24) Install bolts, two long doublers, and nuts in aft flange, boltheads aft, doublers on
forward side of aft flange at boltholes No. 80-96 and No. 1-3.
(25) Tighten aft flange nuts to 135-145 lb in. (15.2-16.3 N·m) of torque.
7. High Pressure Compressor Water Injection (SPRINT®) Kit Installation.
NOTE
This procedure applies to only six configurations of the SPRINT® kit.
The six kits covered are PN 682L294G07, PN 682L294G12, PN
682L874G01, PN 682L903G01, PN 682L903G06, and PN
682L908G01. These instructions apply to all six configurations of
the SPRINT® kit listed above unless otherwise indicated.
A. Remove all access panels from air collector (figure 3).
14
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Figure 8. Electrical Bracket Replacement
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Figure 9. Manifold Support Brackets Removal and Installation
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B. Ensure most inboard bolts of air collector forward flange at 3:00 o’clock and 9:00
o’clock positions are installed with boltheads down (figure 3). If not, remove bolts and
nuts and reinstall with boltheads down. Tighten nut to 480-570 lb in. (54.2-64.4 N·m)
of torque.
C. Install electrical bracket as follows:
(1) Remove bolts (1, figure 8) that secure channel bracket (2) to electrical bracket (5)
on air collector forward flange at 7:00 o’clock position, forward looking aft
(FLA).
(2) Remove self-locking nuts (3) and bolts (4) that secure electrical bracket (5) to air
collector forward flange. Remove and discard bracket.
(3) Reinstall bolt (4) and self-locking nut (3) in bolthole closest to 6:00 o’clock
position, vacated by electrical bracket (5) removal.
(4) Using remaining bolts (4) and self-locking nuts (3), secure electrical bracket (6),
on forward side of flange, bracket tab forward, and body inclined toward
6:00 o’clock position.
(5) Using bolts (1), secure channel bracket (2) to electrical bracket (6). Tighten bolts
to 55-70 lb in. (6.2-7.9 N·m) of torque.
(6) Tighten bolts (4) to 55-70 lb in. (6.2-7.9 N·m) of torque.
CAUTION
Do not remove more than two doublers at a time, or serious engine
damage could result. Install brackets, bolts, and washers in place
of removed doubler(s) before removing next doubler.
D. Remove doublers and install brackets onto LPC aft flange (figure 9) as follows:
(1) Beginning at 12:00 o'clock position, FLA and counting counterclockwise (CCW),
remove self-locking nuts, bolts, and two doublers from LPC aft flange at 12:00
o'clock and 11:00 o'clock positions. Retain bolts and nuts for reuse.
WARNING
Zinc Chromate Primer, TT-P-1757, is highly toxic to skin,
eyes, and respiratory tract. Skin and eye protection, and
vapor control are required. Avoid all contact.
(2) Coat bolt shanks above threads and bearing surfaces of bolts with zinc chromate
primer. Allow primer to air dry.
17
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NOTE
• Except as noted, bolthole on elongated end of bracket base will
not be used to secure brackets
• When installing bracket, L49492G01 or higher, install a bolt, flat
washer, and self-locking nut at the cutouts in the middle of the
bracket. Ensure the bolt head is aft, and the washer is under the
nut.
(3) Lightly coat bolt and nut threads with thread lubricant. Using bolts, boltheads aft,
and self-locking nuts, secure brackets, bracket tabs inclined forward, on forward
side of LPC aft flange at boltholes No. 2, No. 3, No. 4, No. 5, No. 8, No. 9, No. 10,
and No. 11. Tighten bolts to 133-147 lb in. (15.0-16.6 N·m) of torque.
NOTE
A bracket will be installed in a later step in boltholes No. 90, No. 91,
and No. 92.
(4) Install remaining bolts, flat washers, and self-locking nuts in open boltholes in
flange, boltheads aft and washers under nuts, except boltholes No. 90, No. 91, and
No. 92. Tighten nuts to 133-147 lb in. (15.0-16.6 N·m) of torque.
(5) Remove self-locking nuts, bolts, and doubler from LPC aft flange at 9:30 o'clock
position. Retain bolts and nuts for reuse.
(6) Repeat substeps (2), (3), and (4) to install bracket on LPC aft flange at boltholes
No. 15, No. 16, No. 17, and No. 18.
(7) Remove self-locking nuts, bolts, and doubler from LPC aft flange at 8:30 o'clock
position. Retain bolts and nuts for reuse.
NOTE
At 8:30 o'clock and 2:30 o'clock positions, FLA, five bolts and
self-locking nuts are used to install brackets.
(8) Repeat substeps (2), (3), and (4) to install bracket on LPC aft flange at boltholes
No. 24, No. 25, No. 26, No. 27, and No. 28.
(9) Remove self-locking nuts, bolts, and doubler from LPC aft flange at 7:30 o'clock
position. Retain bolts and nuts for reuse.
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(10) Repeat substeps (2), (3), and (4) to install brackets on LPC aft flange at boltholes
No. 29, No. 30, No. 31, No. 32, No. 34, No. 35, No. 36, and No. 37.
(11) Remove self-locking nuts, bolts, and doubler from LPC aft flange at 6:00 o'clock
position. Retain bolts and nuts for reuse.
(12) Repeat substeps (2), (3), and (4) to install bracket on LPC aft flange at boltholes
No. 41, No. 42, No. 43, and No. 44.
(13) Remove self-locking nuts, bolts, and doubler from LPC aft flange at 4:30 o'clock
position. Retain bolts and nuts for reuse.
(14) Repeat substeps (2), (3), and (4) to install bracket on LPC aft flange at boltholes
No. 49, No. 50, No. 51, No. 52, No. 56, No. 57, No. 58, and No. 59.
(15) Remove self-locking nuts, bolts, and doubler from LPC aft flange at 3:30 o'clock
position. Retain bolts and nuts for reuse.
(16) Repeat substeps (2), (3), and (4) to install bracket on LPC aft flange at boltholes
No. 61, No. 62, No. 63, No. 64, No. 66, No. 67, No. 68, and No. 69.
(17) Remove self-locking nuts, bolts, and doubler from LPC aft flange at 2:30 o'clock
position. Retain bolts and nuts for reuse.
(18) Repeat substeps (2), (3), and (4) to install bracket on LPC aft flange at boltholes
No. 72, No. 73, No. 74, No. 75, and No. 76.
(19) Remove self-locking nuts, bolts, and doubler from LPC aft flange at 1:30 o'clock
position. Retain bolts and nuts for reuse.
(20) Repeat substeps (2), (3), and (4) to install bracket on LPC aft flange at boltholes
No. 82, No. 83, No. 84, No. 85, No. 89, No. 90, No. 91, and No. 92.
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E. Install water nozzles as follows:
CAUTION
Ensure variable bypass valves (VBV) are in closed position so
hardware or tools will not fall into front frame.
NOTE
SPRINT® kit, PN 682L294G07, includes water nozzles, PN
L38060P02 (short) and PN L38060P04 (long). Kits PN 682L294G12
and PN 682L874G01, include water nozzles, PN L38060P07 (short)
and PN L38060P098 (long). SPRINT® kits PN 682L903G01, PN
682L903G06, and PN 682L908G01, include water nozzles, PN
L38060G13 (short) and PN L38060G016 (long). The installation
procedure is the same for both sets of water nozzles.
(1) Remove bolts (4, figure 7) and plug (1) from front frame at 12:30 o’clock
position, located just aft of VBV actuation ring (5).
CAUTION
Do not install original double hex head bolts. Use current hex head
bolts. Double hex head bolts may interfere with VBV system
bellcranks. Reference Service Bulletin LM6000-IND-0209.
(2) Using hex head bolts (4), secure short water nozzle (2), at 12:30 o'clock position,
just aft of VBV actuation ring, orienting nozzle with larger nipple to clockwise
(CW) side. Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
(3) Remove bolts (4) and plug (1) at next location CW (FLA) from substep (2).
(4) Using hex head bolts (4), secure long water nozzle (3), in next opening CW (FLA)
with larger nipple to CW side of nozzle. Tighten bolts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
(5) Verify long water nozzle (3) is in correct position. Ensure nozzle is directly
forward of T2.5 sensor on front frame.
(6) Continue installing water nozzles (2 and 3) by alternating short and long nozzles
per substeps (1) through (4) in remaining 22 locations around front frame.
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NOTE
Step F is only required if SPRINT® kit, PN 682L294G12, PN
682L874G01, PN 682L903G01, PN 682L903G06, or PN
682L908G01, is being installed.
F. Install air tube and manifold brackets on engine as follows:
(1) Remove self-locking nuts (1, figure 2) and bolts (2) from first three boltholes and
sixth, seventh, and eighth boltholes, counting from forward end of right side of air
collector horizontal flange. Retain nuts for reuse.
(2) Remove self-locking nuts (1) and bolts (2) from three boltholes on right-side
outer end of air collector horizontal flange aft side. Retain nuts for reuse.
(3) Apply a thin coat of lubricating oil to threads and mating surfaces of nine new
bolts (2).
(4) Place bracket (3), on top surface of air collector horizontal flange, over three
forward boltholes, with bracket tab turned outboard. Secure bracket to flange
using three bolts (2) and self-locking nuts (1) removed in substep (1). Tighten
nuts finger-tight.
(5) Repeat substep (4) for bracket (3) at sixth, seventh, and eighth boltholes on air
collector horizontal flange.
(6) Repeat substep (4) for bracket (3) at three boltholes on right-side outer end of air
collector horizontal flange aft side.
(7) Position bracket (4) at high pressure compressor (HPC) bosses just forward of
stage 2, second and third bosses up from right-side horizontal splitline. Bracket
body goes aft of mounting tab. Secure bracket to bosses using bolts (6). Tighten
bolts finger-tight.
(8) Position bracket (5) at HPC bosses just aft of stage 5, at 2:30 o’clock, aft looking
forward (ALF). Bracket body goes forward of mounting tab. Secure bracket to
bosses using bolts (6). Tighten bolts finger-tight.
G. If installing SPRINT® kit with LPC injection, PN 682L874G01, PN 682L903G01, or
PN 682L903G06, install water nozzles along with air and water tubing and attaching
hardware onto inlet section, per packager’s instructions. Perform dimensional
inspection per packager’s instructions to ensure correct nozzle penetration into
flowpath, then add thread locking compound per packager’s instructions.
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H. Install water tubes as follows:
(1) Remove bolts (8, figure 8) and cover plates (7) that cover water injection tube
access openings in air collector. Discard cover plates and bolts.
(2) Connect B-nut nearest single right-angle bend of water tube (1, figure 4), to water
nozzle just CW (FLA) of 12:00 o'clock position. Tube routes forward through air
collector wall toward brackets installed in step A. Tighten B-nut finger-tight.
(3) Repeat substep (2) for remaining 23 water nozzles (2 and 3, figure 7).
I. Install water manifolds as follows:
NOTE
There are two configurations of water manifolds. The original
configuration has two segments and the current configuration
has three segments.
(1) Position top water manifold (1, figure 6) on LPC stator, with manifold ends at
3:00 o'clock and 9:00 o'clock positions and manifold nipples facing aft, over
brackets (2) installed in step A. Using retaining strap (3), and two bolts (4), secure
top water manifold to bracket at 12:00 o'clock position. Tighten bolts finger-tight.
(2) Using retaining strap (3) and bolts (4) at five remaining locations, secure top
water manifold (1) to brackets (2).
(3) Connect water tubes (1, figure 4) onto top water manifold (1, figure 6) at 12
locations. Tighten B-nuts finger-tight.
(4) Install bottom water manifold (5) on LPC stator. Connect bottom water manifold
onto top water manifold (1) using B-nuts at 3:00 and 9:00 o'clock positions on
original configuration and at 9:00 o'clock position on current configuration.
Tighten B-nuts finger-tight.
(4)A.On current configuration, install middle water manifold (6) to top (1) and bottom
(5) water manifolds at 3:00 o'clock position using B-nuts. Tighten B-nuts
finger-tight.
(5) Using retaining straps (3) and bolts (4), secure bottom water manifold (5) onto
brackets at eight locations. Tighten bolts finger-tight.
(6) Connect water tubes (1, figure 4) onto bottom water manifold (5, figure 6) at
12 locations. Tighten B-nuts finger-tight.
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(7) Ensure minimum 0.060 inch (1.52 mm) clearance exists between water tube at
9:00 o'clock position FLA and air collector horizontal flange. If clearance is under
0.060 inch (1.52 mm), grind air collector horizontal flange as follows:
(a) Remove water tube at 9:00 o’clock position.
WARNING
Do not breathe the particles from grinding or let the particles
touch you. The particles can cause damage, injury, or irritation
to you. Use personal protection equipment. Use local mechanical
exhaust ventilation or an approved respirator.
(b) Grind lower inboard edge of air collector forward flange, figure 6, detail B,
sheet 2.
(c) Prepare area for painting per MIL-C-22750.
WARNING
Epoxy polyamide, MIL-C-22750, is flammable and highly toxic
to skin, eyes, and respiratory tract. Skin and eye protection, and
vapor control are required. Avoid all contact.
(d) Using epoxy paint, color 26307, apply touch-up paint per MIL-C-22750.
(e) Install water tube. Ensure minimum 0.060 inch (1.52 mm) clearance exists
between water tube and air collector flange.
(8) Tighten B-nuts that connect water manifolds (1 and 5, and 6 on current
configuration, figure 6, sheet 1) together at 3:00 o'clock and 9:00 o'clock
positions to 75-91 lb ft (101.6-123.4 N·m) of torque.
(9) Tighten B-nuts that secure water tubes (1, figure 4) to water nozzles
(2 and 3, figure 7) to 135-155 lb in. (15.3-17.5 N·m) of torque.
(10) Tighten B-nuts that secure water tubes (1, figure 4) to water manifold
(1 and 5, figure 6) to 135-155 lb in. (15.3-17.5 N·m) of torque.
(11) Tighten bolts that secure water manifold retaining straps (3) to brackets (2)
to 55-70 lb in. (6.2-7.9 N·m) of torque.
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J. Install air tubes as follows:
(1) Connect B-nut nearest double bend of air tube (2, figure 4) to water nozzle just
CW (FLA) of 12:00 o'clock position (water nozzle No. 1). Tube routes forward
through air collector wall toward brackets installed in step A. Tighten B-nut
finger-tight.
(2) Repeat substep (1) at water nozzles No. 3, No. 4, No. 7, No. 8, No. 11, No. 12, No.
13, No. 16, No. 17, No. 19, No. 20, No. 21, No. 23, and No. 24.
(3) Connect B-nut nearest double bend of air tube (3) to water nozzle No. 2. Tube
routes forward through air collector wall toward brackets installed step A. Tighten
B-nut finger-tight.
(4) Repeat substep (3) at water nozzles No. 5, No. 6, No. 9, No. 10, No. 14, No. 15,
No. 18, and No. 22.
K. On original configuration, install air manifolds as follows:
(1) Using U-bolt (1, figure 5) and two self-locking nuts (2), secure right-side air
manifold (3), to bracket (4), near 12:30 o'clock position (FLA), inlet connector
near 2:00 o'clock position and nipples aft. Tighten nuts finger-tight.
(2) Using six U-bolts (1) and 12 self-locking nuts (2), secure right-side air manifold
(3) to brackets (4) on 9:00 o'clock (FLA) side of LPC. Tighten nuts finger-tight.
(3) Using U-bolt (1) and two self-locking nuts (2), secure left-side air manifold (5), to
bracket (4) near 11:00 o'clock position (FLA). Orient left-side air manifold with
nipples aft and flanges mating with flanges of right side air manifold (3).
(4) Using six U-bolts (1) and 12 self-locking nuts (2), secure left-side air manifold (5)
to brackets (4) at 3:00 o'clock position (FLA) side of LPC. Tighten nuts
finger-tight.
(5) Using bolts (7) and self-locking nuts (8), assemble air manifolds and gaskets (6),
at 12:00 o'clock and 6:00 o'clock positions. Tighten nuts to 100-130 lb in.
(11.3-14.7 N·m) of torque.
K.A Install air manifolds as follows:
(1) Using U-bolt (1, figure 5) and two self-locking nuts (2), secure top air manifold
(9), to bracket (4), near 12:30 o'clock position (FLA), inlet connector near
2:00 o'clock position and nipples aft. Tighten nuts finger-tight.
(2) Using five U-bolts (1) and 12 self-locking nuts (2), secure top air manifold (9) to
remaining brackets (4) on top of LPC. Tighten nuts finger-tight.
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(3) Using U-bolt (1) and two self-locking nuts (2), secure bottom air manifold (10), to
bracket (4) near 6:30 o'clock position (FLA). Orient left-side air manifold with
nipples aft and flanges mating with flanges of right side air manifold (3).
(4) Using seven U-bolts (1) and 12 self-locking nuts (2), secure bottom air manifold
(10) to remaining brackets (4) at bottom of LPC. Tighten nuts finger-tight.
(5) Using bolts (7) and self-locking nuts (8), assemble air manifolds and gaskets (6),
at 3:00 o'clock and 9:00 o'clock positions. Tighten nuts to 100-130 lb in.
(11.3-14.7 N·m) of torque.
L. Connect air tubes (2 and 3, figure 4) to air manifolds (3 and 5, or 9 and 10, figure 5),
finger-tight.
M. Install stage 8 adapter as follows:
NOTE
If installing PN 682L294G12, PN 682L874G01, PN
682L903G01, PN 682L903G06, or PN 682L908G01 go to
step N.
(1) Loosen self-locking nut on coupling clamp, figure 10. Remove coupling clamp,
cover plate, and metal seal ring. Retain coupling clamp for reuse.
(2) Install new metal seal ring in groove of stage 8 adapter. Using coupling clamp,
secure stage 8 adapter and metal seal ring to stage 8 port. Install coupling clamp
with nut aft and outboard.
(3) Tighten nut on coupling clamp to 55-65 lb in. (6.2-7.3 N·m) of torque. Using
soft-face mallet, tap around outside of clamp to ensure complete seating. Tighten
nut to 115-125 lb in. (13.0-14.1 N·m) of torque.
25
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 1916 00
NOTE
Steps N., O., and P. are only required if installing SPRINT® kit, PN
682L294G12, PN 682L874G01, PN 682L903G01, PN 682L903G06,
or PN 682L908G01.
N. Install SPRINT® air manifold as follows:
NOTE
If installing SPRINT® kit, PN 682L294G12, air tube, PN
L52422G01, will be installed in substep (1). If installing SPRINT®
with LPC spray injection kit, PN 682L874G01, PN 682L903G01, PN
682L903G06, or PN 682L908G01, air manifold, PN L52084G01,
will be installed in substep (1).
(1) Position air tube or air manifold (4, figure 1), on outboard and aft sides of brackets
(5) and (6), with right-angle bend of air tube or air manifold forward and mating
with connector on air manifold (10). Secure manifold to bracket (5), at aft end of
air collector horizontal flange, using retaining strap (7), two bolts (8), and two
self-locking nuts (9). Tighten nuts finger-tight.
(2) Secure air tube or air manifold (4) to bracket (5) on forward end of air collector
horizontal flange, bracket (5) on aft side of air collector horizontal flange, and
bracket (6) on HPC stage 1 bosses, using retaining straps (7), bolts (8), and self-
locking nuts (9). Tighten nuts finger-tight.
(3) Place new gasket (11), between flanges of air tube or air manifold (4) and air
manifold (10). Secure gasket and manifold flanges using bolts (12), boltheads
outboard, and self-locking nuts (13). Tighten nuts finger-tight.
O. Install SPRINT® air tube as follows:
(1) Position air tube (14) between stage 8 adapter (3) and air tube or air manifold (4),
S-bend forward. Secure air tube to bracket (15) using retaining strap (7), two bolts
(8), and two self-locking nuts (9). Tighten nuts finger-tight.
(2) Position plate orifice (16) and two gaskets (17) between flange of air tube (14) and
stage 8 adapter (3), one gasket on each side of plate orifice. Secure tube flange,
plate orifice, and gaskets to stage 8 adapter using bolts (18). Tighten bolts
finger-tight.
(3) Position gasket (17) between flanges of air tube (14) and air tube or air manifold
(4). Secure tubes or tube and manifold flanges and gasket using bolts (19),
boltheads aft, and self-locking nuts (20). Tighten nuts finger-tight.
26
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WP 1916 00
P. Tighten tubing connections, brackets, and clamps as follows:
(1) Ensure all tubing installed in steps N. and O. are aligned without strain. Tighten
self-locking nuts (20) at joint of tube or manifold (4) and tube (14) to
100-130 lb in. (11.3-14.7 N·m) of torque.
(2) Tighten bolts (18) securing tube (14) to plate orifice (16) to 100-130 lb in.
(11.3-14.7 N·m) of torque.
(3) Tighten self-locking nuts (13) securing tube or manifold (4) to air manifold (10)
to 100-130 lb in. (11.3-14.7 N·m) of torque.
(4) Tighten bolts (6, figure 2) securing brackets (4) and (5) to HPC case bosses to
55-70 lb in. (6.2-7.9 N·m) of torque and safety-wire.
(5) Tighten self-locking nuts (1) securing three brackets (3) to air collector flanges to
480-570 lb in. (54.2-64.4 N·m) of torque.
(6) Tighten self-locking nuts (9, figure 1) securing five retaining straps (7) to
brackets to (55-70 lb in. (6.2-7.9 N·m) of torque.
Q. Tighten B-nuts that secure air tubes (2 and 3, figure 4) to water nozzles
(2 and 3, figure 7) to 270-300 lb in. (30.5-33.9 N·m) of torque.
R. Tighten B-nuts that secure air tubes (2 and 3, figure 4) to air manifold
(3 and 5, figure 5) to 270-300 lb in. (30.5-33.9 N·m) of torque.
S. Tighten self-locking nuts that secure U-bolts (1, figure 5) to brackets (4) to
190-230 lb in. (21.5-26.0 N·m) of torque.
T. Install cap assembly (figure 11) into instrumentation fitting near upper flange of
right-side air manifold. Tighten cap assembly to 135-155 lb in. (15.3-17.5 N·m) of
torque.
U. Using bolts and flat washers removed in paragraph 6, step D., install air collector
access panels (figure 3). Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
V. Using plastic syringe or other suitable dispenser, inject bead of thread lubricant around
spacers of IGV, stage 1, and stage 2 variable stator vane actuation arms. See figure 12.
Using finger, press bead of thread lubricant into cavity between spacer and stator case
so compound is forced into gap between HPC stator casing and spacer. Thread
lubricant should be applied around at least 180 degrees of upper stator bushings and
approximately 90 degrees around lower stator bushings.
12
11
10
27
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WP 1916 00
Figure 10. Stage 8 Adapter Installation
Figure 11. Cap Assembly
28
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WP 1916 00
Figure 12. Anti-Seize Compound Application
29/(30 Blank)
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WP 2110 00
WP 2110 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE INLET GUIDE VANE (VIGV) ASSEMBLY
REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 10 ...... 0
Alphabetical Index
Subject Page
Variable Inlet Guide Vane Assembly Installation ....................................................................... 7
Variable Inlet Guide Vane Assembly Removal........................................................................... 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2110 00
1. Introduction.
A. This work package contains instructions for removing and installing the variable inlet guide
vane (VIGV) assembly.
B. Remove low pressure compressor temperature/pressure (T2/P2) sensor per WP 1111 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Compressor Inlet Temperature/Pressure WP 1111 00
(T2/P2) Sensor Replacement
Variable Inlet Guide Vane (VIGV) System Check WP 1113 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Hydraulic Actuator Unit 1C3569G3
Fixture Assembly, Lift & Turn - VIGV 1C9390G01
Adapter Set, Pressure Test/Rig - VIGV, 1C9393G01
VBV, VSV
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Marking Pen Sharpie T.E.C.
(Black or Blue)
Soap Solution Local Purchase
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed 9365M41P117 4
Packing, Preformed 9365M41P122 4
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WP 2110 00
6. Variable Inlet Guide Vane Assembly Removal.
A. Using marking pen, mark position of brackets to low pressure compressor (LPC)
stages 0-3 stator case forward flange.
B. Remove VIGV actuators and mount brackets as follows:
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at
installation. Failure to comply may cause unreliable engine
operation.
(1) Tag and disconnect electrical connectors from VIGV actuators.
(2) Disconnect tubing coupling nuts from VIGV actuator fittings as follows
(figure 1):
1
Figure 1. Variable Inlet Guide Vane (VIGV) Tubing
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WP 2110 00
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated
or prolonged contact. Use in well-ventilated area.
(a) Position a waste fluid container beneath VIGV actuator. Disconnect drain
lines from drain adapters.
(b) Disconnect drain adapters from VIGV actuator. Slide drain adapters away
from VIGV actuator ports to expose coupling nuts.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
(c) Disconnect coupling nuts from VIGV actuator fittings.
(d) Remove and discard preformed packings.
(3) Remove nuts and bolts that secure actuator-to-ring brackets to actuation ring. See
figure 2. Remove actuator-to-ring brackets.
2
(4) Remove nuts, bolts, and bushings that secure actuator rod-ends.
(5) Remove nuts and bolts that secure VIGV actuator stationary mount brackets onto
LPC stator case front flange/VIGV stator case rear flange.
(6) Remove nuts and bolts from actuator bearing blocks.
(7) Remove actuators and stationary mount brackets as units.
C. Install lift and turn fixture, 1C9390, as follows (figure 3):
(1) Connect lift and turn fixture, 1C9390, onto 1-ton (907 kg) capacity hoist.
(2) Position lift and turn fixture, 1C9390, onto VIGV assembly forward flange.
(3) Using bolts and washers, secure lift and turn fixture, 1C9390, onto VIGV
assembly forward flange. Boltheads face aft. Tighten bolts to 40-60 lb in.
(4.6-6.7 N·m) of torque.
3
D. Remove nuts, bolts, and washers that secure VIGV assembly aft flange onto LPC
forward flange.
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WP 2110 00
Figure 2. VIGV Actuators and Mount Brackets
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WP 2110 00
Figure 3. VIGV Lift and Turn Fixture Assembly, 1C9390
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WP 2110 00
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
E. Tap VIGV assembly forward flange using soft-face mallet. Move VIGV assembly
forward until aft rabbet clears LPC stages 0-3 stator case forward flange.
7. Variable Inlet Guide Vane Assembly Installation.
A. Install lift and turn fixture, 1C9390, as follows (figure 3):
(1) Connect lift and turn fixture, 1C9390, onto 1-ton (907 kg) capacity hoist.
(2) Position lift and turn fixture, 1C9390, onto VIGV assembly forward flange.
(3) Using bolts and washers, secure lift and turn fixture, 1C9390, onto VIGV
assembly forward flange. Boltheads face aft. Tighten bolts to 40-60 lb in.
(4.6-6.7 N·m) of torque.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
B. Lift VIGV assembly into position on LPC stages 0-3 stator case forward rabbet.
C. Apply thread lubricant to threads and washer faces of bolts that secure VIGV
assembly aft flange to LPC forward flange.
D. Install brackets, bolts, washers, and nuts to secure VIGV assembly aft flange to LPC
forward flange. Boltheads face aft. Washer is under nut at bracket locations. At all
other flange locations, washers are under boltheads and nuts.
E. Tighten nuts to 380-420 lb in. (43.0-47.4 N·m) of torque.
F. Remove bolts and nuts that secure lift and turn fixture, 1C9390, onto VIGV assembly
forward flange. Remove lift and turn fixture.
G. Install VIGV actuators as follows (figure 2):
(1) Install bushings into actuator-to-ring brackets so bushing flanges are to outside of
brackets.
(2) Apply thread lubricant onto threads of actuator rod-end retaining bolt.
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WP 2110 00
(3) Using bolt (bolthead outboard) and nut, secure actuator-to-ring brackets to VIGV
actuator rod-end. Tighten nut to 190-230 lb in. (21.5-25.9 N·m) of torque.
(4) Apply thread lubricant to threads and mating surfaces of bracket retaining nuts.
(5) Align actuator-to-ring brackets with bushings installed in actuation ring. Install
eight bolts (boltheads are outside brackets) and nuts. Tighten nuts to
380-420 lb in. (43.0-47.4 N·m) of torque.
(6) Position VIGV actuator forward and aft stationary mount brackets and electrical
bracket as marked during disassembly.
NOTE
Boltheads will face forward on VIGV actuator stationary mount
flange bolts adjacent to the left speed sensor.
(7) Using bolts and nuts, secure forward and aft stationary mounts, and electrical
bracket, onto VIGV stator case and stages 0-3 stator case. Boltheads face aft,
except for two bolts adjacent to left speed sensor.
(8) Using bolts and nuts, secure actuator bearing blocks onto forward and aft
stationary mounts. Boltheads face forward.
(9) Tighten stationary mount brackets and actuator bearing block bolts and nuts to
380-420 lb in. (43.0-47.4 N·m) of torque.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated
or prolonged contact. Use in well-ventilated area.
(10) Lubricate new packings, P/N 9365M41P117 and P/N 9365M41P122, with
lubricating oil and install in drain adapters. See figure 1.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
(11) Connect tubing to actuator fittings. Tighten coupling nuts to 450-550 lb in.
(50.9-62.1 N·m) of torque.
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WP 2110 00
(12) Leak-check head- and rod-end fittings as follows:
CAUTION
Use hydraulic actuator unit, 1C3569G3, with engines that use
lubricating oil, MIL-L-23699. Do not intermix lubricating oil,
MIL-L-7808 and MIL-L-23699, or damage will occur.
(a) Install reducers from adapter set, 1C9393, on hydraulic actuator unit,
1C3569. Tighten reducers to 135-150 lb in. (15.3-16.9 N·m) of torque.
(b) Disconnect head tube from hydraulic control unit (HCU). Install head tube
onto -4 to -10 reducer. Tighten coupling nut to 360-400 lb in.
(40.7-45.2 N·m) of torque.
(c) Disconnect rod tube from HCU. Install rod tube onto -4 to -8 reducer.
Tighten coupling nut to 270-300 lb in. (30.6-33.9 N·m) of torque.
WARNING
Serious injury can occur when applying hydraulic pressure. Eye
protection is required. Relieve pressure before disconnecting
lines and fittings.
(d) Apply 200-250 psi (1379-1724 kPa) to head tube and hold for a minimum of
2 minutes. Check head tube/actuator connection for leakage.
(e) Apply 200-250 psi (1379-1724 kPa) to rod tube and hold for a minimum of 2
minutes. Check rod tube/actuator connection for leakage.
(f) Check VIGV actuation system per WP 1113 00.
(g) Disconnect hydraulic actuator unit, 1C3569. Remove reducers.
(h) Connect head tube to HCU. Tighten coupling nut to 650-770 lb in.
(73.5-87.0 N·m) of torque.
(i) Connect rod tube to HCU. Tighten coupling nut to 450-550 lb in.
(50.9-62.1 N·m) of torque.
(13) Slide drain adapters over coupling nuts and connect to actuator ports.
Hand-tighten drain adapters.
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WP 2110 00
(14) Leak-check drain adapters as follows:
(a) Connect a source of clean, dry, regulated shop air or nitrogen to drain line
fitting on drain adapter.
WARNING
• Serious injury can occur when applying pneumatic pres-
sure. Eye protection is required. Relieve pressure before
disconnecting lines and fittings.
• Nitrogen, BB-N-411, can displace oxygen in enclosed
areas. Use in a well-ventilated area.
(b) Apply 50-55 psi (345-379 kPa) to drain adapter. Shut off pressure and
monitor. Pressure shall not drop off more than 10 psi (69 kPa) in 2 minutes.
(c) If pressure drop limit is exceeded, use soap solution to detect leak. Repair, as
required, and repeat leak check.
(d) Disconnect test equipment from drain adapter.
(e) Connect drain lines to drain adapters. Tighten coupling nuts to 270-300 lb in.
(30.6-33.9 N·m) of torque.
(15) Connect electrical connector to VIGV actuator as follows:
(a) Engage connector with mating interface and turn knurled coupling ring while
wiggling back shell assembly.
(b) After fully seating connector by hand, apply final torque to coupling ring
using Teflon-jawed connector pliers. Torque connector 1/4-1/2 turn or until
plier slippage occurs.
(c) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
NOTE
It may be necessary to loosen lead clamps that restrict mating.
(d) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamp that restrict mating.
10
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SWP 2110 01
0SWP 2110 01
SUBORDINATE WORK PACKAGE
TECHNICAL PROCEDURES
INLET FRAME REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 0
6 Blank ...... 0
Alphabetical Index
Subject Page
Inlet Frame Installation ............................................................................................................... 3
Inlet Frame Removal................................................................................................................... 3
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SWP 2110 01
1. Introduction.
This Subordinate work package contains instructions for removing and installing the inlet frame
assembly.
2. Reference Material.
Prior to performing the tasks herein, remove the low pressure compressor (LPC)
temperature/pressure (T2/P2) sensor.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Compressor Inlet Temperature/Pressure
(T2/P2) Sensor Replacement WP 1111 00
3. Support Equipment.
Nomenclature Part No.
Fixture Assembly, Lift & Turn - VIGV 1C9390G01
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
None required.
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SWP 2110 01
6. Inlet Frame Removal.
A. Using marking pen, matchmark brackets to LPC stages 0-3 stator case forward flange.
B. Install lift and turn fixture, 1C9390, as follows (figure 1):
(1) Connect lift and turn fixture, 1C9390, onto 1-ton (907 kg) capacity hoist.
(2) Position lift and turn fixture, 1C9390, onto inlet frame assembly forward flange.
(3) Using bolts and washers, secure lift and turn fixture, 1C9390, onto inlet frame
assembly forward flange. Boltheads face aft. Tighten bolts to 40-60 lb in.
(4.6-6.7 N·m) of torque.
1
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
C. Remove nuts, bolts, and washers that secure aft flange onto LPC forward flange.
D. Tap forward flange using a soft-face mallet. Move forward until aft rabbet clears LPC
stages 0-3 stator case forward flange.
7. Inlet Frame Installation.
A. Install lift and turn fixture, 1C9390, as follows (figure 1):
(1) Connect lift and turn fixture, 1C9390, onto 1-ton (907 kg) capacity hoist.
(2) Position lift and turn fixture, 1C9390, onto inlet frame assembly forward flange.
(3) Using bolts and washers, secure lift and turn fixture, 1C9390, onto inlet frame
assembly forward flange. Boltheads face aft. Tighten bolts to 40-60 lb in.
(4.6-6.7 N·m) of torque.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
B. Lift inlet frame assembly into position on LPC stages 0-3 stator case forward rabbet.
C. Apply thread lubricant onto threads and washer faces of bolts that secure aft flange to
LPC forward flange.
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SWP 2110 01
Figure 1. Lift and Turn Fixture Assembly, 1C9390
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SWP 2110 01
NOTE
The two bolts adjacent to the left speed sensor boltheads face forward.
D. Install brackets, bolts, washers, and nuts that secure inlet frame assembly aft flange
onto LPC forward flange. Boltheads face aft, except for two bolts that are adjacent to
left speed sensor. Washer is under nut at bracket locations. At all other flange
locations, washers are under boltheads.
E. Tighten nuts to 380-420 lb in. (43.0-47.4 N·m) of torque.
F. Remove bolts and nuts that secure lift and turn fixture, 1C9390, onto inlet frame
assembly forward flange. Remove lift and turn fixture.
5/(6 Blank)
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WP 2210 00
2WP 2210 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR (LPC) MODULE
REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 14
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 14 ...... 2
Alphabetical Index
Subject Page
Low Pressure Compressor Module Installation .......................................................................... 8
Low Pressure Compressor Module Removal.............................................................................. 3
Change 2 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2210 00
1. Introduction.
A. This work package contains instructions for removing and installing the low pressure
compressor (LPC) module.
B. Disconnect and connect electrical leads and connecting tubes between LPC module and gas
turbine per SWP 1913 04.
C. Remove and install the variable inlet guide vane (VIGV) per WP 2110 00 or inlet frame
assembly SWP 2111 01.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Bypass Valve (VBV) System Check WP 1312 00
Engine Assembly External Tubing, Harnesses, and Clamping SWP 1913 04
Variable Inlet Guide Vane (VIGV) Assembly Replacement WP 2110 00
Inlet Frame Replacement SWP 2110 01
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Dolly, LPC Rotor and Stator - Vertical 1C9052G01
Fixture, Lift and Turn - LPC Rotor and Stator 1C9053G01
Fixture, Lift - LPC Rotor and Stator, Horiz 1C9054G02
Fixture, Lift - LPC Rotor and Stator, Fwd 1C9116G01
Tool Set, Jackscrew 1C9150G02
Adapter, Support/Lift - LPC 1C9317G01
Fixture, LPC Rotor and Stator Support 1C9385G01
Guide Pin - Fan Rotor Installation 2C6348P02
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Marking Pen Sharpie T.E.C.
(Black or Blue)
Petrolatum Fed Spec VV-P-236
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed 9607M05P21 1
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6. Low Pressure Compressor Module Removal.
A. Remove forward manifold as follows (figure 1):
(1) Using marking pen, matchmark forward manifold and forward drive adapter.
(2) Remove bolts that secure forward manifold onto forward drive adapter.
(3) Using four jackscrews from jackscrew tool set, 1C9150, remove forward
manifold.
1
B. Install LPC support/lift adapter, 1C9317, and LPC horizontal lift fixture, 1C9054, as
follows:
(1) Install LPC forward lift fixture, 1C9116, onto LPC horizontal lift fixture, 1C9054,
at position marked 1C9054. Secure with quick-release pin. See figure 2.
2
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(2) Connect 4-ton (3,629 kg) capacity hoist onto LPC forward lift fixture, 1C9116.
Lift horizontal lift fixture into position on LPC support/lift adapter, 1C9317.
Secure with two quick-release pins.
(3) Reposition hoist onto LPC horizontal lift fixture, 1C9054.
(4) Position LPC support/lift adapter, 1C9317, so that inner ring boltholes align with
forward drive adapter boltholes.
(5) Using 16 bolts and nuts, secure LPC support/lift adapter, 1C9317, inner ring onto
forward drive adapter. Tighten nuts to 160-210 lb in. (18.1-23.7 N·m) of torque.
(6) Using 56 equally spaced screws and nuts, secure outer ring of LPC support/lift
adapter, 1C9317 onto stator case forward flange. Tighten nuts to 160-210 lb in.
(18.1-23.7 N·m) of torque.
C. Separate LPC module from fan shaft assembly as follows:
(1) If necessary to gain access, move actuation ring to aftmost position by actuating
variable bypass valve (VBV) doors to fully closed. Refer to WP 1312 00.
(2) Remove bolts that secure LPC aft fan case aft flange onto front frame forward
face.
(3) Remove bolts, washers, and nuts that secure rotor shaft onto fan shaft assembly.
Change 2 3
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Figure 1. Low Pressure Compressor (LPC) Module
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Figure 2. LPC Support/Lift Adapter, 1C9317, and LPC Horizontal Lift Fixture, 1C9054
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NOTE
Perform step (4) only if same LPC module will be reinstalled.
(4) Using marking pen, matchmark rotor shaft to forward fan shaft assembly.
WARNING
Use correct lifting equipment and techniques. Stay out from under
suspended loads to prevent injury.
CAUTION
Use care to keep LPC rotor horizontal during disengagement from
fan shaft assembly to prevent rotor damage.
(5) Pull rotor forward from fan shaft. Simultaneously support LPC rotor using
overhead hoist. Closely monitor disengagement to prevent damage.
(6) Move LPC module forward, beyond No. 1 bearing seal.
(7) Remove and discard preformed packing from rotor shaft. See figure 3.
3
Figure 3. Packing Installation
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NOTE
If LPC module is to be placed forward end down for stage 3 stator
vane or stage 4 rotor blade replacement, proceed to step E.
D. Install LPC module onto LPC support fixture, 1C9385, as follows (figure 4):
(1) Move LPC module clear of gas turbine.
(2) Install LPC forward lift fixture, 1C9116, onto LPC horizontal lift fixture, 1C9054,
at location marked 1C9050, LPCR. Secure with quick-release pin.
(3) Connect second 4-ton (3,629 kg) capacity hoist onto LPC forward lift fixture,
1C9116.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(4) Rotate LPC module so that forward end is up.
(5) Remove hoist from LPC horizontal lift fixture, 1C9054.
(6) Position LPC support fixture, 1C9385, beneath supended LPC module.
(7) Lower LPC module onto LPC support fixture, 1C9385, and secure with washers
and nuts.
(8) Remove nuts and bolts that secure LPC support/lift adapter, 1C9317, onto LPC
module.
(9) Install LPC forward lift fixture, 1C9116, onto LPC horizontal lift fixture, 1C9054,
at location marked 1C9054. Secure with quick-release pin.
(10) Connect hoist onto LPC forward lift fixture, 1C9116. Lift assembled LPC
horizontal lift fixture, 1C9054, and LPC support/lift adapter, 1C9317, from LPC
assembly.
NOTE
If LPC module has been installed in LPC support fixture, 1C9385,
per step D., disregard step E.
E. Install LPC module into LPC vertical dolly, 1C9052, as follows:
(1) Move LPC module clear of gas turbine.
4
(2) Install LPC lift and turn fixture, 1C9053, into bore of LPC rotor shaft.
See figure 5.
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(3) Attach forward end of LPC lift and turn fixture, 1C9053, onto LPC horizontal lift
fixture, 1C9054. Secure with quick-release pin.
(4) Attach second 4-ton (3,629 kg) capacity hoist onto eye of LPC lift and turn fixture,
1C9053.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(5) Rotate LPC module so that forward end is down.
(6) Remove hoist from LPC horizontal lift fixture, 1C9054.
(7) Position LPC vertical dolly, 1C9052, beneath suspended LPC module.
(8) Lower LPC module onto LPC vertical dolly, 1C9052, so that LPC horizontal lift
fixture, 1C9054, is between dolly supports. Remove quick-release pin and remove LPC
lift and turn fixture, 1C9053. See figure 6.
(9) Install forward lift fixture, 1C9116, onto horizontal lift fixture, 1C9054, at location
marked 1C9054, 1C9050. Secure using quick-release pin.
(10) Connect hoist to forward lift fixture, then lift assembled horizontal lift fixture, 1C9054,
and adapter, 1C9317, from LPC assembly.
7. Low Pressure Compressor Module Installation.
NOTE
If LPC module is in a forward end down position, proceed to step B
A. Install LPC support/lift adapter, 1C9317, and LPC horizontal lift fixture, 1C9054, as
follows:
(1) Install LPC forward lift adapter, 1C9116, onto LPC horizontal lift fixture, 1C9054, at
position marked 1C9054. Secure with quick-release pin. See figure 2.
(2) Connect 4-ton (3,269 kg) capacity hoist onto LPC forward lift fixture, 1C9116. Lift
LPC horizontal lift fixture, 1C9054, into position on LPC support/lift adapter, 1C9317.
Secure with two quick-release pins.
(3) Move LPC forward lift fixture, 1C9116, into position marked 1C9054, 1C9050. Secure
with quick-release pin.
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Figure 4. LPC Rotor and Stator Support Fixture, 1C9385
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(4) Position LPC support/lift adapter, 1C9317, so that inner ring boltholes align with
forward drive adapter boltholes.
(5) Using 16 bolts and nuts, secure LPC support/lift adapter, 1C9317, inner ring onto
forward drive adapter outer flange. Tighten nuts to 160-210 lb in. (18.1-23.7 N·m) of
torque.
(6) Using 56 equally spaced screws and nuts, secure outer ring of LPC support/lift adapter,
1C9317, onto LPC stages 0-3 stator case forward flange. Tighten nuts to 160-210 lb in.
(18.1-23.7 N·m) of torque.
(7) Move LPC forward lift fixture, 1C9116, to position marked 1C9054, 1C9050, LPCR.
Secure with quick-release pin.
(8) Connect second 4-ton (3,269 kg) capacity hoist onto LPC horizontal lift fixture, 1C9054.
WARNING
Use correct lifting equipment and techniques. Stay out from under sus-
pended loads to prevent injury.
(9) Lift and rotate LPC module into horizontal position. Remove LPC forward lift fixture,
1C9116.
NOTE
If LPC module has been rotated to the horizontal position per step A., proceed to
step C.
B. Install LPC lift and turn fixture, 1C9053, as follows:
(1) Connect 4-ton (3,269 kg) capacity hoist onto LPC lift and turn fixture, 1C9053.
(2) Install LPC lift and turn fixture, 1C9053, into bore of LPC rotor shaft. See figure 5.
(3) Attach forward end of LPC lift and turn fixture, 1C9053, onto LPC horizontal lift fixture,
1C9054. Secure with quick-release pin (part of 1C9054).
(4) Attach second 4-ton (3,629 kg) capacity hoist onto LPC horizontal lift fixture, 1C9054.
WARNING
Use correct lifting equipment and techniques. Stay out from under sus-
pended loads to prevent injury.
(5) Lift and rotate LPC module into horizontal position.
1
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5
Figure 5. LPC Lift and Turn Fixture, 1C9053
Change 2 11
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(6) Remove hoist from LPC lift and turn fixture, 1C9053.
(7) Remove LPC lift and turn fixture, 1C9053.
(8) Adjust center of gravity of LPC horizontal lift fixture, 1C9054, until LPC module is
horizontal.
C. Lubricate new preformed packing, PN 9607M05P21, with petrolatum, and install into rotor
shaft preformed packing groove. See figure 3.
D. Install guide pins, 2C6348P02, at three equally spaced locations on fan shaft flange.
CAUTION
If same LPC rotor is being installed, ensure that alignment marks are aligned
properly. Failure to comply will require that LP section be balanced.
E. If same LPC module is being installed, align matchmark on rotor shaft with that on fan shaft
assembly.
F. Position LPC module so that offset boltholes at top vertical centerline align.
G. Push LPC module aft so that aft fan case aft flange mates with forward face of front frame
and aft rabbet of rotor shaft mates with fan shaft assembly. Ensure flanges and shafts are fully
seated.
H. Remove three guide pins, 2C6348P02.
I. Apply thread lubricant onto threads of bolts and onto threads and washer faces of nuts which
secure rotor shaft onto fan shaft assembly.
J. Using bolts, washers, and nuts, secure rotor shaft onto fan shaft assembly. Boltheads face aft,
washers under nuts.
K. Tighten nuts to 275-285 lb ft (372.9-386.4 N·m) of torque. Bolts shall not rotate during
torquing. Loosen nuts one half turn, then retighten to 275-285 lb ft (372.9-386.4 N·m) of
torque. Wipe excess lubricant from nut.
L. Loosen bolts that secure LPC support/lift adapter, 1C9317, onto LPC stages 0-3 stator case.
See figure 4.
M. Apply thread lubricant to threads of bolts which secure aft fan case aft flange onto front
frame forward face.
N. Using bolts, secure aft fan case aft flange onto front frame forward face.
O. Tighten bolts to 100-130 lb in. (11.3-14.6 N·m) of torque.
12 Change 2
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6
Figure 6. LPC Vertical Dolly, 1C9052
Change 2 13
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P. Remove LPC horizontal lift fixture, 1C9054, and LPC support/lift adapter, 1C9317.
See figure 2.
Q. Install forward manifold as follows:
(1) Apply thread lubricant to threads of bolts that secure forward manifold to forward
drive adapter. See figure 1.
(2) Install forward manifold onto forward drive adapter, aligning matchmarks. Secure
with bolts.
(3) Tighten bolts to 100-120 lb in. (11.3-13.5 N·m) of torque.
14 Change 2
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WP 2211 00
WP 2211 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR (LPC) STAGE 0
ROTOR BLADES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1-9 ...... 4
10 Blank . . . . . . 4
Alphabetical Index
Subject Page
LPC Stage 0 Rotor Blades Installation ....................................................................................... 5
LPC Stage 0 Rotor Blades Removal ........................................................................................... 3
Part Rework - Tip Grinding to Obtain Blade Tip to Stator Case Clearance ............................... 8
Replacement Blades Selection .................................................................................................... 5
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WP 2211 00
1. Introduction.
A. This work package contains instructions for removing and installing low pressure compressor
(LPC) stage 0 rotor blades.
B. Remove variable inlet guide vane (VIGV) assembly per WP 2110 00 or inlet frame assembly
per SWP 2110 01 to gain access.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Inlet Guide Vane (VIGV) Assembly Replacement WP 2110 00
Inlet Frame Replacement SWP 2110 01
3. Support Equipment.
Nomenclature Part No.
Program, Balance - Blade Replacement 9446M61G02
(or latest CD-Rom version)
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
Molybdenum Disulfide Lubricant MIL-L-25681
Sharpening Stone Fed Spec SS-S-736
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
None required.
2 Change 4
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WP 2211 00
6. LPC Stage 0 Rotor Blades Removal.
See figure 1.
A. Remove blade retainer as follows:
CAUTION
Ensure matchmarks are not erased during maintenance.
Improper installation of components will cause rotor imbal-
ance.
NOTE
The following procedure is for replacement of any number of LPC
stage 0 rotor blades. Instructions for grinding blade tips to meet
clearance requirements are included. If an entire stage of blades
requires replacement, contact General Electric Customer Service
Representative to obtain a set of preground blades.
(1) Using marking pen, matchmark blade retainer to stage 0 disk.
(2) Using marking pen, mark location of balance bolts.
1
Figure 1. LPC Stage 0 Rotor Blade Replacement
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(3) Remove balance bolts, washers, and nuts. Maintain each balance bolt and related
washer and nut together as a set.
(4) Weigh each balance bolt set and record on position map (figure 2).
(5) Remove bolts, washers, and nuts that secure blade retainer. Maintain each bolt and
related washer and nut together as a set. Remove blade retainer.
B. Using marking pen, position mark stage 0 blades to be removed and corresponding
dovetail slot on stage 0 disk. If all stage 0 rotor blades are being replaced, position
mark No. 1 and No. 5 dovetail slots on stage 0 disk.
C. Measure blade tip to stator case clearance of blades being replaced as follows:
(1) Pull blade radially outward. Shake blade to ensure it is at its most outward
position.
(2) Measure clearance between blade tip and edge of stator case. Measurement may
be taken from any area on blade tip, provided each blade is measured from the
same area. Record clearance.
(3) Repeat steps (1) and (2) for each blade requiring replacement.
D. Slide stage 0 blade forward to remove.
2
Figure 2. LPC Stage 0 Blade/Balance Bolt Position Map
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7. Replacement Blades Selection.
A. Weigh removed blades and record on position map (figure 2).
NOTE
Replacement blades shall be weighed after tip grinding to meet
clearance requirement.
B. Weigh replacement blades. Mark weight on blade using marking pen.
NOTE
If individual stage 0 rotor blades are being replaced, select blades
per step C. If all stage 0 rotor blades are being replaced, calculate
blade position per step D.
C. Select replacement blade within 0.5 gram of original blade. Blades replacing those
with portions missing shall weigh within 0.5 gram of the average of eight serviceable
blades. If replacement blade within 0.5 gram of original blade is not available, use
blade replacement guide (figure 3).
NOTE
For a copy of GE computerized balance program and instructions
for use, contact GE customer service.
3
D. Calculate blade position using GE computerized balance program, 9446M61. Mark
position on replacement blade using marking pen.
8. LPC Stage 0 Rotor Blades Installation.
A. Apply molybdenum disulfide lubricant to pressure surfaces of stage 0 blade dovetails.
See figure 4
4
B. Slide stage 0 blade into corresponding dovetail slot in stage 0 disk. See figure 1.
NOTE
If preground blades are installed, proceed to step D.
C. Measure blade tip to stator case clearance as follows:
(1) Pull blade radially outward. Shake blade to ensure it is at its most outward
position.
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Figure 3. Blade Replacement Guide
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Figure 4. Blade Dovetail Pressure Surface
(2) Measure clearance between blade tip and edge of stator case. Take measurement
from same area on replacement blade tip as that used to measure replaced blade
clearance.
(3) Repeat steps (1) and (2) for each blade requiring replacement.
D. Apply thread lubricant to threads of all nuts and bolts.
CAUTION
Ensure run-on torque for all nuts is a minimum of 5 lb in.
(0.6 N·m) to ensure integrity of locking feature.
E. Align matchmark on blade retainer with matchmark on stage 0 disk and install blade
retainer. Secure blade retainer with 12 equally spaced nuts, washers, and bolts,
boltheads aft, washer under nut.
F. Tighten nuts to 190-220 lb in. (21.5-24.8 N·m) of torque. Back off nuts one-half turn,
then tighten to 190-220 lb in. (21.5-24.8 N·m) of torque.
G. Install remaining bolts, washers, and nuts that secure blade retainer, boltheads aft,
washer under nut.
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H. Tighten nuts to 190-220 lb in. (21.5-24.8 N·m) of torque. Back off nuts one-half turn,
then tighten to 190-220 lb in. (21.5-24.8 N·m) of torque.
I. Install balance bolts, washers, and nuts into previously marked positions, boltheads
aft, washer under nut. Tighten nuts to 70-90 lb in. (8.0-10.1 N·m) of torque.
A minimum of 0.060 inch (1.52 mm) of threads shall protrude beyond nut after
torquing.
9. Part Rework - Tip Grinding to Obtain Blade Tip to Stator Case Clearance.
CAUTION
• Do not use hard abrasive grinding wheels to tip grind
blades. Damage to blades may occur.
• To avoid contamination of titanium blades, do not use
sharpening stones that have been used on other metals.
A. Hand-blend replacement blade tip using sharpening stone and observe the following:
(1) Minimum and maximum blade clearance for stage 0 is shown on figure 5.
Replacement blade shall not exceed length of longest blade in stage 0, or be
shorter than shortest blade in stage 0.
(2) Do not remove more than 0.007 inch (0.178 mm) of material from blade tip.
(3) Maintain original contour of blade.
B. Break all edges 0.005-0.015 inch (0.127-0.381 mm).
5
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2211 00
Figure 5. LPC Stage 0 Rotor Blade to Stator Case Clearance
Change 4 9/(10 Blank)
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WP 2212 00
0WP 2212 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR (LPC) STAGES 0-3
UPPER AND LOWER STATOR CASE REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 12
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 12 ...... 0
Alphabetical Index
Subject Page
LPC Stages 0-3 Lower Stator Case Installation.......................................................................... 6
LPC Stages 0-3 Lower Stator Case Removal ............................................................................. 6
LPC Stages 0-3 Upper and Lower Stator Cases Removal .......................................................... 3
LPC Stages 0-3 Upper Stator Case Installation .......................................................................... 8
LPC Stages 0-3 Upper Stator Case Removal .............................................................................. 5
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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WP 2212 00
1. Introduction.
A. This work package contains instructions for removing and installing the low pressure
compressor (LPC) stages 0-3 upper and lower stator cases, with engine installed in
maintenance dolly.
B. If upper and lower LPC stator cases are being removed, remove the VIGV assembly
WP 2110 00 or inlet frame assembly per SWP 2110 01.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Inlet Guide Vane (VIGV) Assembly Replacement WP 2110 00
Inlet Frame Replacement SWP 2110 01
3. Support Equipment.
Nomenclature Part No.
Fixture, Lift - LPC Case, Stages 0-3 1C9602G01
Pliers, Teflon-Jawed Local Purchase
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
Thread Lubricant GE Spec A50TF201
Zinc Chromate Primer Fed Spec TT-P-1757
5. Expendable Material.
None required.
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WP 2212 00
6. LPC Stages 0-3 Upper and Lower Stator Cases Removal.
NOTE
If only the upper stator case requires removal, proceed to paragraph 7.
A. Remove variable inlet guide vane (VIGV) assembly per WP 2110 00 or inlet frame
assembly per SWP 2110 01.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
NOTE
If VIGV kit is installed, perform steps B, and C
B. Position waste fluid container beneath hydraulic control unit (HCU). Disconnect
variable inlet guide vane (VIGV) tubing coupling nuts from HCU fittings. Install
protective caps/plugs. See figure 1.
1
C. Disconnect VIGV actuator drain line flexible hose from drain line manifold.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure location of electrical connector is noted to aid at installa-
tion. Failure to comply may cause unreliable engine operation.
D. Tag and disconnect electrical connectors at No. 1 electrical interface panel.
E. Remove nuts and bolts that secure No. 1 electrical interface panel aft support bracket
onto air collector.
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Figure 1. No. 1 Electrical Interface Panel, VIGV Tubing, Channel Bracket, and Electrical Cables
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2212 00
F. Remove nuts and bolts that secure channel bracket tray onto rear electrical panel
support bracket.
G. Using marking pen, mark location of brackets.
H. Remove No. 1 electrical interface panel, VIGV tubing and brackets (if installed),
channel bracket, and electrical cables and brackets as a unit.
I. Remove LPC stages 0-3 upper stator case per paragraph 7.
J. Remove LPC stages 0-3 lower stator case per paragraph 8
7. LPC Stages 0-3 Upper Stator Case Removal.
NOTE
If both upper and lower stator cases require removal, proceed to step B.
A. If only upper stator case requires removal, remove and disconnect the following:
(1) Disconnect T2 electrical lead from bracket clips on upper case forward flange.
NOTE
If VIGV kit is installed, perform steps (2) and (3).
(2) Disconnect left VIGV hydraulic actuator from upper (stationary) bracket.
(3) Disconnect right VIGV hydraulic actuator from actuation ring bracket.
B. Remove bolts, nuts, and washers from forward and aft flanges of stages 0-3 upper
case. Remove and retain doublers.
C. Remove bolts, nuts, and washers that secure horizontal flanges of stages 0-3 case. If
necessary, gently tap five body-bound bolts on each horizontal flange using hammer
and nylon drift to release bolts.
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WP 2212 00
D. Attach lift fixture, 1C9602, onto forward and aft flanges of stages 0-3 upper case.
Seefigure 2.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
E. Attach 1-ton (907 kg) capacity overhead hoist to lift fixture. Lift stages 0-3 upper case
free of gas turbine and place on suitable pallet using care not to damage horizontal
flange surfaces or internal hardware. If new case will be installed, transcribe bracket
matchmarks to new case using marking pen.
8. LPC Stages 0-3 Lower Stator Case Removal.
A. Remove bolts, nuts, and washers that secure aft flange of stages 0-3 lower case to aft
fan case. Remove and retain doublers.
NOTE
Nylon straps may be used to lower or elevate the lower stator case.
Attach hoist to nylon straps.
B. Place nylon straps under stages 0-3 lower case. Raise straps to support stages 0-3
lower case. See figure 3.
2
3
C. Remove bolts, nuts, and washers that secure horizontal flanges of stages 0-3 case. If
necessary, gently tap five body-bound bolts on either horizontal flange using hammer
and nylon drift to release bolts.
D. Slowly lower stages 0-3 lower case. If new case is to be installed, transcribe bracket
matchmarks to new case using marking pen.
9. LPC Stages 0-3 Lower Stator Case Installation.
A. Position stages 0-3 lower case under LPC rotor using nylon straps and hoist. See
figure 3.
B. Slowly raise stages 0-3 lower case until LPC stator case aft flange and aft fan case
forward flange boltholes align.
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Figure 2. LPC Stages 0-3 Case Lift Fixture, 1C9602
Figure 3. LPC Stator Lower Case Support
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WARNING
Zinc Chromate Primer, TT-P-1757, is highly toxic to skin,
eyes, and respiratory tract. Skin and eye protection, and
vapor control are required. Avoid all contact.
C. Apply zinc chromate primer onto shank and bearing surface of bolts which secure aft
circumferential flange of stages 0-3 case onto aft fan case. Allow primer to air dry.
D. Apply thread lubricant onto threads and bearing surface of aft circumferential flange
bolts.
E. Install bolts and nuts into aft circumferential flange, boltheads aft, doublers on forward
side of aft circumferential flange. Tighten nuts finger-tight.
10. LPC Stages 0-3 Upper Stator Case Installation.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
A. Position stages 0-3 upper case over LPC rotor using lift fixture, 1C9602, and a 1-ton
(907 kg) capacity overhead hoist. Inspect flanges for cleanliness.
B. Install washers on five body-bound bolts.
C. Install body-bound bolts, boltheads down, through lower stator case. Install bolts into
horizontal flange bolthole numbers 1, 4, 9, 13, and 17 (boltholes are counted from
forward flange) on both sides of stator case. See figure 4.
CAUTION
Be careful when mating upper and lower stages 0-3 case halves. The
inner shrouds have interlocking features at the horizontal split-lines.
The upper and lower stator shrouds shall be properly engaged as the
case halves are mated. Do not force case halves together. Failure to
comply will result in LPC stator damage.
D. Slowly lower stages 0-3 upper case until horizontal flanges are mated. Use flashlight
to ensure that shrouds interlock properly.
E. Remove lift fixture, 1C9602.
F. Install washers and nuts onto body-bound bolts. Tighten nuts finger-tight.
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WARNING
Zinc Chromate Primer, TT-P-1757, is highly toxic to skin, eyes,
and respiratory tract. Skin and eye protection, and vapor control
are required. Avoid all contact.
G. Apply zinc chromate primer onto shanks and bearing surfaces of remaining bolts and
washers which secure horizontal flanges together. Also apply zinc chromate primer
onto inside diameter of boltholes these bolts go through.
4
NOTE
Casing assembly procedure: L refers to 9:00 o'clock position flange
and R refers to 3:00 o'clock position flange. See figure 4.
H. Install remaining horizontal flange bolts, washers, and nuts, boltheads up, with washer
under each nut and each bolthead. Tighten nuts on nonbody-bound bolts, left to right,
in ascending order 2L, 2R, 3L, 3R, 5L, 5R, etc., to 200-220 lb in. (22.6-24.9 N·m) of
torque.
I. Tighten horizontal flange nuts on body-bound bolts in ascending order 1L, 1R, 4L,
4R, 9L, 9R, etc., to 200-220 lb in. (22.6-24.8 N·m) of torque.
WARNING
Zinc Chromate Primer, TT-P-1757, is highly toxic to skin, eyes,
and respiratory tract. Skin and eye protection, and vapor control
are required. Avoid all contact.
J. Apply zinc chromate primer onto shank and bearing surface of bolts which secure aft
circumferential flange. Allow primer to dry.
K. Apply thread lubricant onto threads and bearing surfaces of aft circumferential flange
bolts.
L. Install bolts, doublers, and nuts in aft circumferential flange, boltheads aft, doublers
on forward side of aft circumferential flange.
M. Tighten all aft circumferential flange nuts to 135-145 lb in. (15.3-16.3 N·m) of torque.
N. Remove nylon straps.
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Figure 4. LPC Stages 0-3 Stator Case Horizontal Flanges
10
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NOTE
If the VIGV assembly is not installed, proceed to step P.
O. If VIGV assembly or inlet frame assembly is installed, complete the following steps.
(1) Install brackets, bolts, washers, and nuts into forward circumferential flange per
WP 2110 00.
(2) Connect VIGV hydraulic actuators per WP 2110 00.
(3) Install T2 electrical lead into bracket clips on upper case forward flange.
NOTE
If the VIGV assembly is installed, disregard the remaining steps.
P. Install assembled No. 1 electrical interface panel, VIGV tubing and brackets, channel
bracket, and electrical cables and brackets as a unit. Align brackets at locations
marked at removal. See figure 1.
Q. Using bolts and nuts, secure No. 1 electrical interface panel aft mount brackets onto
air collector flange. Tighten nuts to 480-570 lb in. (54.3-64.4 N·m) of torque.
R. Using bolts and nuts, secure channel bracket to rear electrical panel support bracket.
Tighten nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
S. Connect electrical connectors at No. 1 electrical interface panel locations tagged at
removal as follows. Remove tags.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(1) Engage connector with mating interface and turn knurled coupling ring while
wiggling back shell assembly.
(2) After fully seating connector by hand, apply final torque to coupling ring using
Teflon-jawed pliers. Torque connector 1/4-1/2 turn, or until plier slippage occurs.
(3) Check for full seating by wiggling accessory assembly. There shall be no
movement with respect to mating connector.
11
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NOTE
It may be necessary to loosen lead clamps that restrict mating.
(4) Repeat substeps (2) and (3), as required. It may be necessary to loosen lead
clamps that restrict mating.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
T. Connect VIGV actuator drain line flexible hose onto drain line manifold. Tighten
coupling nut to 135-150 lb in. (15.3-16.9 N·m) of torque.
U. Connect tubes to HCU. Tighten head tube coupling nut to 360-400 lb in.
(40.6-45.2 N·m) of torque. Tighten rod tube coupling nut to 270-300 lb in.
(30.5-33.9 N·m) of torque.
V. Install VIGV assembly WP 2110 00 or inlet frame assembly per SWP 2110 01.
12
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WP 2213 00
4WP 2213 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR (LPC) STAGES 0-3
STATOR VANES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1-9 ...... 1
10 Blank . . . . . . 1
Alphabetical Index
Subject Page
LPC Stages 0-3 Stator Vanes Installation.................................................................................... 4
LPC Stages 0-3 Stator Vanes Removal ....................................................................................... 2
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1. Introduction.
A. This work package contains instructions for removing and installing the low pressure
compressor (LPC) stages 0-3 stator vanes.
B. To gain access, remove stages 0-3 LPC upper and lower stator cases per WP 2212 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Compressor (LPC) Stages 0-3 Upper and Lower WP 2212 00
Stator Case Replacement
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Thread Lubricant GP460
Isopropyl Alcohol Fed Spec TT-I-735
Silicone Adhesive Sealant GE Spec A15F6B6
(RTV 106)
Zinc Chromate Primer Fed Spec TT-P-1757
5. Expendable Material.
None required.
6. LPC Stages 0-3 Stator Vanes Removal.
A. Place upper and lower stator cases on a skid or table, aft end up.
B. Remove nuts, bolts, and washers from stage 3 inner shrouds. See figure 1.
1
CAUTION
Use care when separating forward and aft shroud sections to prevent
damage from prying tool.
C. Separate forward shroud section from aft shroud section. If necessary, pry between forward
and aft shroud sections to separate them. Remove shroud.
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Figure 1. LPC Stator Assembly
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D. Remove vane bushings from vane inner diameter.
E. Remove two screws and locking strip from each stator case half horizontal flange.
F. Slide vanes circumferentially until they can be removed from slot in stator case.
G. Remove dovetail liners. See figure 2.
H. Repeat steps B. through G for stages 2, 1, and 0.
7. LPC Stages 0-3 Stator Vanes Installation.
A. Install dovetail liners in vane slots. See figure 2. If necessary, grind ends to allow
assembly. The gap between any two adjacent liner segments shall not exceed
0.030 inch (0.76 mm).
2
Figure 2. LPC Dovetail Liners Installation
B. Slide stage 3 vanes circumferentially into lined slots. See figure 3. Adjust quantity of
A and D vanes to obtain required clearance (Dimension K) on each half of case.
Dimension K shall be met prior to installing shrouds. During stage 1, 2, and 3 vane
installation, install borescope vane so that a 0.405 inch (10.287 mm) diameter rod will
pass freely through case and platform of vane.
4
3
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Figure 3. LPC Stator Vane Location
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CAUTION
Fumes from adhesive may damage natural gas sensors.
Ensure natural gas sensors are protected from fumes.
C. If natural gas sensors are installed in area, encase sensor heads in plastic bags and seal
with tie wraps to protect sensors.
WARNING
Vapor from uncured sealant is flammable and toxic to skin, eyes,
and respiratory tract. Avoid contact with skin and eyes. Use in a
well-ventilated area.
CAUTION
No adhesive is allowed on any mating shroud surface or outer
flow-path surface, or shroud misassembly may occur.
NOTE
• Steps E, F, and G apply to stage 3 vanes and shroud installation
after Service Bulletin LM6000-IND-212
• Silicone adhesive sealant is applied during stage 3 inner shroud
bushing assembly. Silicone adhesive sealant should be allowed to
cure for minimum of 8 hours before engine operation.
• Ensure shim is installed and securely adhered to bottom of stage 3
bushing.
D. Apply thin layer of silicone adhesive sealant to outer surface of new stage 3 fan
booster bushing assemblies except flowpath surfaces, as well as vane-to-bushing
interface, inside bushing vane tang slot. See figure 4.
E. While adhesive is still wet, install 3 vane bushing assemblies onto vane tangs.
F. While adhesive is still wet, install stage 3 shroud.
G. Apply thread lubricant to threads and friction surface of shroud nuts.
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Figure 4. Application of Silicone Adhesive Sealant to Tabbed Bushings
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NOTE
Section of shroud with seal is aft on stages 0, 1, and 3. Section of
shroud with seal is forward on stage 2.
H. Install aft section of shroud so that vane bushings fit into each semicircle cup.
I. On stages 0, 1, and 2, install vane bushings onto vane tangs.
J. Install forward section of shroud so bushings fit in semicircular cups. Hold both
shroud sections together and install bolts, washers, and nuts in each end and center of
shroud. Install one washer under bolthead (boltheads aft), and one washer under nut.
Tighten nuts finger-tight.
K. Install remaining bolts, washers, and nuts in same orientation as step M.or N.
CAUTION
Ensure run-on torque for all nuts is a minimum of 5 lb in. (0.6
N·m) to ensure integrity of locking feature.
NOTE
Only a few PC model Gas Turbines have an original configuration
LPC stator assembly with different size bolts in stages 0,1, and 2
shrouds.
L. On original configuration, tighten nuts to appropriate torque values as follows:
(1) Tighten six 0.250–29 stage 0 nuts to 62-68 lb in. (7.0-7.7 N·m) of torque. Tighten
forty-four 0.312-24 nuts to 109-121 lb in. (12.4-13.6 N·m) of torque.
(2) Tighten six 0.190-32 stage 1 nuts to 35-39 lb in. (4.0-4.4 N·m) of torque. Tighten
twenty-eight 0.250-28 nuts to 62-68 lb in. (7.0-7.7 N·m) of torque.
(3) Tighten six 0.190-32 stage 2 nuts to 35-39 lb in. (4.0-4.4 N·m) of torque. Tighten
fifty 0.250-28 nuts to 62-68 lb in. (7.0-7.7 N·m) of torque.
(4) Tighten six 0.190-32 stage 3 nuts to 35-39 lb in. (4.0-4.4 N·m) of torque.
Tighten thirty0.250-28 nuts to 62-68 lb in. (7.0-7.6 N·m) of torque.
M. On current configuration, tighten nuts to appropriate torque values as follows:
(1) Tighten fifty 0.250-29 stage 0 nuts to 62-68 lb in. (7.0-7.7 N·m) of torque.
(2) Tighten forty-four 0.250-28 stage 1 nuts to 62-68 lb in. (7.0-7.7 N·m) of torque.
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(3) Tighten fifty-six 0.250-28 stage 2 nuts to 62-68 lb in. (7.0-7.7 N·m) of torque.
(4) Tighten six 0.190-32 stage 3 nuts to 35-39 lb in. (4.0-4.4 N·m) of torque. Tighten
thirty 0.250-28 nuts to 62-68 lb in. (7.0-7.7 N·m) of torque.
WARNING
Vapor from uncured sealant is flammable and toxic to skin, eyes,
and respiratory tract. Avoid contact with skin and eyes. Use in a
well-ventilated area.
N. Apply silicone adhesive sealant over ends of nuts to cover exposed bolt threads.
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
O. Using isopropyl alcohol, remove excess silicone adhesive sealant.
P. Repeat steps A. through D. and steps H. through P. for stages 1, 2, and 3.
WARNING
Zinc Chromate Primer, TT-P-1757, is highly toxic to skin, eyes,
and respiratory tract. Skin and eye protection, and vapor control
are required. Avoid all contact.
Q. Install locking strip on each stator case half. Secure with screws coated with wet zinc
chromate primer. Tighten screws to 24-26 lb in. (2.7-2.9 N·m) of torque.
R. Allow silicone adhesive sealant to cure for minimum of 8 hours before operating
engine.
S. If applicable, remove protective plastic bags from natural gas sensors prior to engine
operation.
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WP 2214 00
5WP 2214 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR (LPC) STAGES 1-3
ROTOR BLADES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 12
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 11 ...... 4
12 Blank . . . . . . 4
Alphabetical Index
Subject Page
LPC Stages 1-3 Rotor Blades Installation................................................................................... 6
LPC Stages 1-3 Rotor Blades Removal ...................................................................................... 3
Part Rework - Tip Grinding to Obtain Blade Tip to Stator Case Clearance ............................... 10
Replacement Blades Selection .................................................................................................... 6
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WP 2214 00
1. Introduction.
A. This work package contains instructions for removing and installing low pressure compressor
(LPC) stages 1-3 rotor blades.
B. Remove LPC stages 0-3 upper stator case to gain access per WP 2212 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Compressor (LPC) Stages 0-3 Upper and Lower
Stator Case Replacement WP 2212 00
3. Support Equipment.
Nomenclature Part No.
Program, Balance - Blade Replacement 9446M61G02
(or latest CD-Rom version)
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
Molybdenum Disulfide Lubricant MIL-L-25681
Penetrating Oil GE Spec A50TF54,
CL-A
Sharpening Stone Fed Spec SS-S-736
5. Expendable Material.
None required.
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6. LPC Stages 1-3 Rotor Blades Removal.
CAUTION
Ensure matchmarks are not erased during maintenance. Improper
installation of components will cause rotor imbalance.
NOTE
This procedure is for removal of any number of LPC stages 1-3 rotor
blades. Instructions for grinding blade tips to meet clearance
requirements are included in paragraph 7. If an entire stage of
blades requires replacement, contact General Electric Customer Ser-
vice Representative to obtain a set of preground blades.
A. Position mark blades using marking pen. See figure 1, view B. Blade 1 is first blade to
right of right locking lug (aft looking forward).
1
B. Measure blade tip to lower stator case clearance of blades being replaced as follows:
(1) Pull blade radially outward. Shake blade to ensure it is at its most outward
position.
(2) Measure clearance between blade tip and edge of lower stator case. Measurement
may be taken from any area on blade tip, provided each blade is measured from
the same area. Record clearance.
(3) Repeat steps (1) and (2) for each blade requiring replacement.
C. Mark centerline of locking lugs on outside diameter of disk or spool using marking
pen.
D. Apply penetrating oil to setscrews and allow to soak for 15 minutes.
E. Loosen setscrews of two locking lugs until lugs will slip below surface of retaining
slot sufficiently to permit circumferential movement of blades.
F. Rotate entire stage of blades circumferentially (in either direction) approximately
one-half the width of blade platform, until one blade can be removed from loading
slot. If necessary, tap blades as close to platform as possible using hammer and nylon
drift.
G. Slide locking lug to loading slot and remove. Record on position map. See figure 2.
2
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Figure 1. Typical LPC Stages 1-3 Rotor Blade Replacement
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Figure 2. Stages 1-3 Blade/Balance Weight Position Map
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H. Remove remaining blades, other locking lug, and all balance weights from stage being
removed. Mark and record position of balance weights on position map as removed.
Weigh each balance weight and record on position map.
7. Replacement Blades Selection.
A. Weigh removed blades and record on position map. See figure 2.
NOTE
Replacement blades shall be weighed after tip grinding to meet clearance
requirement.
B. Weigh replacement blades. Mark weight on blade using marking pen.
NOTE
If individual rotor blades are being replaced, select blades per
step C. If all rotor blades in a stage are being replaced, calculate
blade position per step D.
C. Select replacement blade within 0.5 gram of original blade. Blades replacing those
with portions missing shall weigh within 0.5 gram of the average of eight serviceable
blades. If replacement blade within 0.5 gram is not available, use blade replacement
guide. See figure 3.
NOTE
For a copy of GE computerized balance program and instructions for
use, contact GE customer service.
3
D. Calculate blade position using GE computerized balance program, 9446M61. Mark
position on replacement blade using marking pen.
8. LPC Stages 1-3 Rotor Blades Installation.
A. Ensure locking lug centerline locating marks are still visible. Mark again, if necessary.
B. Apply molybdenum disulfide lubricant to pressure surfaces of blade dovetails.
See figure 4.
4
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Figure 3. Blade Replacement Guide
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Figure 4. Blade Dovetail Pressure Surface
CAUTION
• Ensure balance weights, locking lugs, and reinstalled blades are
replaced in exact positions from which they were removed.
• Ensure replacement blades are installed in positions calculated
in paragraph 7. Failure to comply can result in engine damage.
C. Install blades and balance weights. See figure 1.
D. Install two locking blades, one on each side of loading slot, so cutout on blade
platform faces loading slot.
E. Install locking lugs as follows:
(1) Install setscrews in each of two locking lugs. Run setscrews in and out twice, full
length of threads.
8 Change 4
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 2214 00
NOTE
Run-on torque is the torque value observed while the setscrew is in
motion during one full revolution in the lug. Breakaway torque is
the torque required to start an installed screw rotating in the lug,
with no axial load on the lug (screw is not seated and is stationary
at initiation of torque). Threads of setscrew and lug must be clean
and free of lubricant.
(2) After completion of second cycle, record run-on torque of each screw. Also,
check breakaway torque of each screw. Replace setscrew or locking lug if
breakaway torque is less than 8 lb in. (0.9 N·m).
(3) Install two locking lugs, one on each side of loading slot. Ensure slope of locking
lug follows slope of blade platform.
F. Install one locking blade so cutout on blade platform faces locking lug.
G. Rotate entire stage of blades approximately one-half the width of blade platform, or
until last blade can be installed. Install last locking blade so cutout on blade platform
faces locking lug.
H. Rotate entire stage of blades in the opposite direction until locking lugs align with
position marks on disk or spool.
I. Slide blades circumferentially away from an outside locking blade. Measure
clearance between blade platforms. Total accumulated clearance shall be within 0.010-
0.020 inch (0.25-0.51 mm). If this requirement is not met, replace blade or blades
adjacent to locking blades with narrow or wide platform blades of equal weight.
J. Check each blade for shingling of platforms. If blade tends to shingle, replace with
blade of equal weight.
NOTE
If preground blades are installed, proceed to step L.
K. Measure blade tip to lower stator case clearance as follows:
(1) Pull blade radially outward. Shake blade to ensure it is at its most outward
position.
(2) Measure clearance between blade tip and edge of lower stator case. Take
measurement from same area on replacement blade tip as that used to measure
replaced blade clearance.
(3) Repeat substeps (1) and (2) for each blade requiring replacement.
Change 4 9
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2214 00
L. Tighten setscrews in locking lugs to 19-21 lb in. (2.2-2.3 N·m) of torque above the run-
on torque recorded in step E.(2). Top of the locking lug must be even with, or a maxi-
mum of 0.025 inch (0.64 mm) below, top of blade platform when blade is fully
extended radially.
9. Part Rework - Tip Grinding to Obtain Blade Tip to Stator Case Clearance.
CAUTION
Do not use hard abrasive grinding wheels to tip grind blades. Damage
to blades may occur.
A. Hand-blend replacement blade tip using sharpening stone. Observing the following:
(1) Minimum and maximum blade clearance for each stage is shown in figure 5.
Replacement blade shall not exceed length of longest blade in stage, or be shorter
than shortest blade in stage.
5
(2) Do not remove more than 0.007 inch (0.178 mm) of material from blade tip.
(3) Maintain original contour of blade.
B. Break all edges 0.005-0.015 inch (0.127-0.381 mm).
10 Change 4
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2214 00
Figure 5. LPC Stages 0-3 Rotor Blade to Stator Case Clearance
Change 4 11/(12 Blank)
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2215 00
0WP 2215 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR (LPC) AFT FAN
CASE REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-4 ...... 0
Alphabetical Index
Subject Page
Aft Fan Case Installation............................................................................................................. 3
Aft Fan Case Removal ................................................................................................................ 3
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 2215 00
1. Introduction.
A. This work package contains instructions for removing and installing low pressure compressor
(LPC) aft fan case.
B. Remove LPC module and install in LPC rotor and stator vertical dolly, 1C9052, per
WP 2210 00. See figure 1.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Compressor (LPC) Module Replacement WP 2210 00
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Thread Lubricant GE Spec A50TF201
Zinc Chromate Primer Fed Spec TT-P-1757
5. Expendable Material.
None required.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 2215 00
6. Aft Fan Case Removal.
A. Remove nuts, bolts, and doublers that secure forward flange of aft fan case to aft
flange of LPC stages 0-3 stator case (figure 1).
1
B. Tap gently around circumference of aft fan case aft flange using plastic face hammer.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
CAUTION
Use care when removing LPC aft fan case to avoid damaging LPC
stage 4 rotor blades.
C. Lift aft fan case from LPC module.
7. Aft Fan Case Installation.
A. Install aft fan case over LPC stage 4 rotor blades.
B. Ensure aft fan case forward flange is fully seated against LPC stages 0-3 stator case aft
flange.
WARNING
Zinc Chromate Primer, TT-P-1757, is highly toxic to skin, eyes,
and respiratory tract. Skin and eye protection, and vapor control
are required. Avoid all contact.
C. Apply zinc chromate primer onto shank and bearing surface of bolts. Allow primer to
air dry.
D. Lubricate threads of bolts and threads and bearing surfaces of nuts using thread
lubricant. Install bolts, doublers, and nuts to secure aft fan case forward flange. Dou-
blers are on forward side of LPC stages 0-3 stator case aft flange. Boltheads face aft.
E. Tighten all nuts at forward flange to 130-150 lb in. (14.7-16.9 N·m) of torque.
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2215 00
Figure 1. LPC Module Installed in LPC Rotor and Stator Vertical Dolly, 1C9052
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2216 00
0WP 2216 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR (LPC) STAGE 4
STATOR VANES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-4 ...... 0
Alphabetical Index
Subject Page
Stage 4 Stator Vanes Installation................................................................................................. 3
Stage 4 Stator Vanes Removal .................................................................................................... 3
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2216 00
1. Introduction.
A. This work package contains instructions for removing and installing the stage 4 stator vanes.
B. Remove low pressure compressor (LPC) module to gain access per WP 2210 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Compressor (LPC) Module Replacement WP 2210 00
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
Silicone Rubber Adhesive GE Spec A15F6B6
(RTV 106)
5. Expendable Material.
None required.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 2216 00
6. Stage 4 Stator Vanes Removal.
A. Remove stage 4 stator vane retaining bolts, as required. See figure 1.
1
CAUTION
Ensure bumpers are removed with vanes, or damage to part may
occur.
B. Remove stage 4 stator vanes and bumpers.
7. Stage 4 Stator Vanes Installation.
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
A. Clean front frame bumper slots and outer surface of bumpers using isopropyl alcohol.
See figure 1.
WARNING
Vapor from uncured sealant is flammable and toxic to skin, eyes,
and respiratory tract. Avoid contact with skin and eyes. Use in a
well-ventilated area.
B. Apply a thin layer of silicone rubber adhesive onto bumper slots in front frame.
C. Install stage 4 stator vane bumpers onto stator vane, rounded portion aft.
NOTE
Ensure stator vane bumpers remain in position during stator vane
installation.
D. Install stage 4 stator vanes while silicone rubber adhesive is still wet.
E. Wipe off excess silicone rubber adhesive.
F. Install retaining bolts. Tighten bolts to 55-70 lb in. (6.3-7.9 N·m) of torque.
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WP 2216 00
Figure 1. Stage 4 Stator Vane
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WP 2217 00
5WP 2217 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE COMPRESSOR (LPC) STAGE 4
ROTOR BLADES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 4
Alphabetical Index
Subject Page
LPC Stage 4 Rotor Blades Installation ....................................................................................... 7
LPC Stage 4 Rotor Blades Removal ........................................................................................... 3
Replacement Blades Selection .................................................................................................... 3
Change 4 1
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 2217 00
1. Introduction.
A. This work package contains instructions for removing and installing low pressure compressor
(LPC) stage 4 rotor blades.
B. Remove aft fan case to gain access per WP 2215 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Compressor (LPC) Aft Fan Case Replacement WP 2215 00
3. Support Equipment.
Nomenclature Part No.
Program, Balance - Blade Replacement 9446M61G02
(or latest CD-Rom version)
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
Molybdenum Disulfide Lubricant MIL-L-25681
Penetrating Oil GE Spec A50TF54,
CL-A
5. Expendable Material.
None required.
2 Change 4
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2217 00
6. LPC Stage 4 Rotor Blades Removal.
CAUTION
Ensure matchmarks are not erased during maintenance. Improper
installation of components will cause rotor imbalance.
A. Using marking pen, position mark blades per 1 and 2, figure 1, view B. Blade 1 is first
blade to right of right locking lug (3) (aft looking forward).
1
B. Using marking pen, mark centerline of locking lugs (3) on outside diameter of spool.
C. Apply penetrating oil onto setscrews (4) and allow to soak for 15 minutes.
D. Loosen setscrews (4) of two locking lugs (3) until lugs slip below surface of retaining
slot sufficiently to permit circumferential movement of blades (1 and 2).
E. Rotate entire stage of blades circumferentially (in either direction) approximately
one-half the width of blade base, until one blade can be removed from loading slot. If
necessary, tap blades as close to platform as possible, using hammer and nylon drift.
F. Slide locking lug to loading slot and remove. Record on position map. See figure 2.
3
2
G. Remove remaining blades (1 and 2, figure 1), other locking lug (3), and all balance
weights (5) from stage being removed. Mark and record position of balance weights
on position map as removed. Weigh each balance weight and record on position map.
7. Replacement Blades Selection.
A. Weigh removed blades and record on position map. See figure 2.
B. Weigh replacement blades. Using marking pen, mark weight on blade.
NOTE
If individual rotor blades are being replaced, select blades per
step C. If all rotor blades in a stage are being replaced, calculate
blade position per step D.
C. Select replacement blade within 0.5 gram of original blade. Blades replacing those
with portions missing shall weigh within 0.5 gram of the average of eight serviceable
blades. If replacement blade within 0.5 gram is not available, use blade replacement
guide. See figure 3.
Change 4 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2217 00
Figure 1. Typical LPC Stage 4 Rotor Blade Replacement
4 Change 4
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WP 2217 00
Figure 2. Stage 4 Blade/Balance Weight Position Map
Change 4 5
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WP 2217 00
Figure 3. Blade Replacement Guide
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WP 2217 00
NOTE
For a copy of GE computerized balance program and instructions
for use, contact GE customer service.
D. Calculate blade position using GE computerized balance program, 9446M61. Using
marking pen, mark position on replacement blade.
8. LPC Stage 4 Rotor Blades Installation.
A. Ensure locking lug centerline locating marks are still visible. Mark again, if necessary.
B. Apply molybdenum disulfide lubricant to pressure surfaces of blade dovetails.
See figure 4.
CAUTION
• Ensure balance weights, locking lugs, and reinstalled blades
are replaced in exact positions from which they were removed.
• Ensure replacement blades are installed in positions calculated
in paragraph 7.
C. Install blades and balance weights. See figure 1.
D. Install two locking blades (2), one on each side of loading slot, so cutout on blade
platform faces loading slot.
4
E. Install locking lugs as follows:
(1) Install setscrews (4) into each of two locking lugs (3). Run setscrews in and out
twice, full length of threads.
NOTE
Run-on torque is the torque value observed while the setscrew is in
motion during one full revolution in the lug. Breakaway torque is the
torque required to just start an installed setscrew rotating in the lug,
with no axial load on the lug (setscrew is not seated and is stationary
at initiation of torque). Threads of setscrew and lug must be clean
and free of lubricant.
(2) After completion of second cycle, record run-on torque of each setscrew. Also,
check breakaway torque of each setscrew. Replace setscrew (4) or locking
lug (3) if breakaway torque is less than 8 lb in. (0.9 N·m).
(3) Install two locking lugs (3), one on each side of loading slot. Ensure slope of
locking lug follows slope of blade platform.
Change 4 7
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WP 2217 00
Figure 4. Blade Dovetail Pressure Surface
F. Install one locking blade (2) so cutout on blade platform faces locking lug.
G. Rotate entire stage of blades approximately half the width of a blade platform, or until
last blade can be installed. Install last locking blade so cutout on blade platform faces
locking lug.
H. Rotate entire stage of blades in the opposite direction until locking lugs align with
position marks on disk or spool.
I. Move all blades in a fan out direction, away from an outside locking blade (2).
Measure clearance between blade platforms. Total accumulated clearance shall be
within 0.001-0.010 inch (0.025-0.254 mm) at narrowest point along axial length of
platform. Clearance at other axial positions shall not exceed 0.030 inch (0.762 mm). If
this requirement is not met, replace blade or blades adjacent to locking blades with
narrow or wide platform blades of equal weight.
J. Check each blade (1 and 2) for shingling of platforms. Replace any blade that tends to
shingle with a blade of equal weight.
K. Tighten setscrews (4) into locking lugs (3) to 19-21 lb in. (2.2-2.3 N·m) of torque
above the run-on torque recorded in step E.(2). The top of the locking lug must be even
with, or a maximum of 0.025 inch (0.64 mm) below, the top of the blade platform
when blade is fully extended radially.
8 Change 4
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WP 2310 00
0WP 2310 00
WORK PACKAGE
TECHNICAL PROCEDURES
FRONT FRAME AIR COLLECTOR REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 18
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 17 ...... 5
18 Blank . . . . . . 5
Alphabetical Index
Subject Page
Lower Left Air Collector Section Installation ............................................................................ 13
Lower Left Air Collector Section Removal................................................................................ 11
Lower Right Air Collector Section Installation .......................................................................... 9
Lower Right Air Collector Section Removal.............................................................................. 7
Transfer Gearbox Mount Plate Installation................................................................................. 17
Transfer Gearbox Mount Plate Removal .................................................................................... 16
Upper Air Collector Section Installation .................................................................................... 6
Upper Air Collector Section Removal ........................................................................................ 3
Change 5 1
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 2310 00
1. Introduction.
This work package contains instructions for removing and installing the front frame air collector.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
3. Support Equipment.
Nomenclature Part No.
Jack, Lowering - Engine Components 1C5654G03
Fixture, Lift - Air Collector 1C9300G01
Bottle Jack Local Purchase
4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
Molybdenum Disulfide Lubricant MIL-L-25681
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
None required.
2 Change 5
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2310 00
6. Upper Air Collector Section Removal.
NOTE
• Engine must be removed from the enclosure prior to removal of the upper
air collector section. Do not support the gas turbine by the air collector
in the maintenance stand or support pedestals.
• The upper air collector section weighs 375 lb (170 kg).
A. Ensure variable bypass valve (VBV) doors are in closed position so hardware or tools will not
fall into compressor front frame (CFF).
B. Using four bolts, washers, and nuts, install air collector lift fixture, 1C9300, onto upper air
collector section. See figure 1. Boltheads face up, washers under nuts. Tighten nuts to
420-510 lb in. (47.5-57.6 N·m) of torque.
1
C. Connect 1-ton (907 kg) capacity overhead hoist to lift fixture.
D. Remove bolts that secure actuator seal to upper air collector section. See figure 2. Remove
actuator seal.
2
E. Remove bolts, washers, and four access panels from upper air collector section.
F. Remove screws that secure frame seals to upper air collector section at 3:00 and
9:00 o'clock positions.
G. Remove nuts and bolts that secure upper air collector section to CFF forward flange.
H. Using marking pen, mark location of CFF aft flange brackets and cut safety on bolts securing
upper air collector to CFF aft flange.
I. Before Service Bulletin LM6000-IND-0258, remove bolts securing upper air collector section
and brackets to CFF aft flange.
J. After Service Bulletin LM6000-IND-0258, remove bolts and spacers securing upper air
collector section and brackets to CFF aft flange.
K. Remove nuts and bolts that secure upper air collector section horizontal flanges to lower air
collector sections.
WARNING
Use correct lifting equipment and techniques. Stay out from under sus-
pended loads to prevent injury.
L. Lift upper air collector section clear of engine.
Change 5 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2310 00
Figure 1. Air Collector Lift Fixture, 1C9300
4 Change 5
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WP 2310 00
Figure 2. Upper Air Collector Section
Change 5 5
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WP 2310 00
7. Upper Air Collector Section Installation.
A. Using four bolts, washers, and nuts, install air collector lift fixture, 1C9300, onto upper
air collector section. See figure 1. Boltheads face up, washers under nuts. Tighten nuts
to 420-510 lb in. (47.5-57.6 N·m) of torque.
B. Connect 1-ton (907 kg) capacity overhead hoist to air collector lift fixture, 1C9300.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
CAUTION
Use care when installing upper air collector section to avoid damaging
frame seals.
C. Lift upper air collector section onto CFF and align boltholes.
D. Before Service Bulletin LM6000-IND-0258, apply molybdenum disulfide lubricant to
threads and washer faces of all bolts and nuts.
E. After Service Bulletin LM6000-IND-0258, apply molibdenum disulfide lubricant to
threads and washer faces of all bolts and nuts, except apply thread lubricant to bolts
used to secure upper air collector section onto CFF aft flange.
F. Using bolts and nuts (boltheads face aft), secure upper air collector section onto CFF
forward flange. See figure 2. Tighten nuts finger-tight.
G. Before Service Bulletin LM6000-IND-0258, install aft flange brackets at positions
marked at disassembly. Using bolts, secure upper air collector section and brackets
onto CFF aft flange. Tighten bolts finger-tight.
CAUTION
Do not use spacer with the attachment bolt installed at the 12:00
o’clock position. Installing spacer at this position can result in engine
hardware interference with air collector lift fixture. This can cause
damage to engine hardware and lift fixture.
H. After Service Bulletin LM6000-IND-0258, install aft flange brackets at posi-
tions marked at disassembly. Using bolt only (no spacer) at 12:00 o’clock posi-
tion and using bolts with spacers at remaining positions, secure upper air
collector section and brackets onto CFF aft flange. Tighten bolts finger-tight.
I. Using bolts and nuts (boltheads face up), secure air collector horizontal flanges.
Tighten nuts to 480-570 lb in. (54.3-64.4 N·m) of torque.
J. Before Service Bulletin LM6000-IND-0258, tighten aft flange bolts to 55-70 lb in.
(6.3-7.9 N·m) of torque. Safety-wire bolts.
6 Change 5
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WP 2310 00
K. After Service Bulletin LM6000-IND-0258, tighten aft flange bolts to 106-124 lb in.
(12.0-14.0 N·m) of torque. Safety wire bolts.
L. Tighten forward flange nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
M. Using screws, secure frame seals onto upper air collector section at 3:00 and
9:00 o'clock positions. Tighten screws to 55-70 lb in. (6.3-7.9 N·m) of torque.
N. Using bolts, secure actuator seal onto upper air collector section. Tighten bolts to
55-70 lb in. (6.3-7.9 N·m) of torque.
CAUTION
All tools or maintenance items shall be accounted for upon job
completion, or damage to engine could result.
O. Before installing access panels, perform thorough, final inspection for tools or foreign
objects left in air collector.
P. Using washers and bolts, secure access panels onto upper air collector section.
Tighten bolts to 55-70 lb in. (6.3-7.9 N·m) of torque.
Q. Remove air collector lift fixture.
8. Lower Right Air Collector Section Removal.
. NOTE
The lower right air collector section weighs 170 lb (77 kg).
A. Position bottle jack, with protective block, to support transfer gearbox assembly.
NOTE
If the upper air collector section is installed, proceed to step C
B. If upper air collector section is removed, install air collector lift fixture, 1C9300, onto
lower right air collector section with two bolts, washers, and nuts. See figure 1.
Boltheads face up, washers are under nuts. Tighten nuts to 420-510 lb in.
(47.5-57.6 N·m) of torque.
NOTE
If the upper air collector section is removed, proceed to step D
C. If upper air collector section is installed, secure lift sling to lower right air collector
section. Use holes in top flange gussets for sling attachment points.
D. Connect 1-ton (907 kg) capacity overhead hoist to lift fixture or sling. Take up slack
on hoist.
E. Remove bolts and washers that secure two access panels from lower right air collector
section. See figure 3.
F. Remove screws that secure frame seal onto lower right air collector section.
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Figure 3. Lower Right Air Collector Section
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G. Remove nuts and bolts that secure lower right air collector section onto CFF forward
flange.
H. Before Service Bulletin LM6000-IND-0258, cut safety wire and remove bolts that
secure lower right air collector section onto CFF aft flange.
I. After Service Bulletin LM6000-IND-0258, cut safety wire and remove bolts and
spacers securing lower right air collector section to CFF aft flange.
J. Using marking pen, mark location of lower right air collector flange brackets. Remove
nuts and bolts that secure lower right air collector section onto transfer gearbox mount
plate and onto upper air collector section.
K. Loosen bolts that secure support bracket to No. 1 electrical interface panel. Position
support bracket clear of air collector.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
L. Slowly lower hoist while pulling lower right air collector section clear of engine.
9. Lower Right Air Collector Section Installation.
NOTE
If the upper air collector section is installed, proceed to step B.
A. If upper air collector section is removed, install air collector lift fixture, 1C9300, onto
lower right air collector section using two bolts, washers, and nuts. See figure 1.
Boltheads face up, washers under nuts. Tighten nuts to 420-510 lb in. (47.5-57.6 N·m)
of torque.
NOTE
If the upper air collector section is removed, proceed to step C.
B. If upper air collector section is installed, secure lift sling onto lower right air collector
section. Use holes in top flange gussets for sling attachment points.
C. Connect 1-ton (907 kg) capacity overhead hoist to lift fixture or sling.
Change 5 9
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WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
CAUTION
Use care when installing lower air collector section to avoid damaging
frame seals.
D. Carefully position lower right air collector section onto transfer gearbox mount plate
flange. See figure 3.
E. Before Service Bulletin LM6000-IND-0258, apply molybdenum disulfide lubricant
onto threads and washer faces of all nuts and bolts.
F. After Service Bulletin LM6000-IND-0258, apply molybdenum disulfide lubricant to
threads and washer faces of all bolts and nuts, except apply thread lubricant to bolts
used to secure lower right air collector section onto CFF aft flange.
G. If upper air collector section is installed, secure lower right air collector section onto
upper section with bolts and nuts. Boltheads face up. Tighten nuts finger-tight.
H. Install brackets at positions marked at disassembly. Using bolts and nuts, secure lower
right air collector section and brackets onto transfer gearbox mount plate. Boltheads
face outboard. Tighten nuts finger-tight.
I. Using bolts and nuts, secure lower right air collector section onto CFF forward flange.
Boltheads face aft. Tighten nuts finger-tight.
J. Before Service Bulletin LM6000-IND-0258, using bolts, secure lower right air collec-
tor section onto CFF aft flange. Tighten bolts to 55-70 lb in. (6.3-7.9 N·m) of torque.
Safety-wire bolts.
K. After Service Bulletin LM6000-IND-0258, using bolts and spacers, secure lower
right air collector section onto CFF aft flange. Tighten bolts to 106-124 lb in.
(12.0-14.0 N·m) of torque. Safety-wire bolts.
L. Tighten air collector section flange nuts to 480-570 lb in. (54.2-64.4 N·m) of torque.
Tighten bolts securing support bracket to No. 1 electrical interface panel to 55-70 lb in.
(6.3-7.9 N·m) of torque.
M. Tighten CFF forward flange nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
N. Using screws, secure frame seal onto lower right air collector. Tighten screws to
55-70 lb in. (6.3-7.9 N·m) of torque.
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CAUTION
All tools or maintenance items shall be accounted for upon job
completion, or damage to engine could result.
O. Before installing access panels, perform thorough, final inspection for tools or foreign
objects left in air collector.
P. Using washers and bolts, secure access panels onto lower right air collector section.
Tighten bolts to 55-70 lb in. (6.3-7.9 N·m) of torque.
Q. Remove air collector lift fixture or lift sling.
R. Remove bottle jack from under transfer gearbox assembly.
10. Lower Left Air Collector Section Removal.
NOTE
The lower left air collector section weighs 170 lb (77 kg).
A. Position bottle jack, with protective block, to support transfer gearbox assembly.
NOTE
If the upper air collector section is installed, proceed to step C.
B. If upper air collector section is removed, install air collector lift fixture, 1C9300, onto
lower left air collector section using two bolts, washers, and nuts. See figure 1.
Boltheads face up, washers under nuts. Tighten nuts to 420-510 lb in. (47.5-57.6 N·m)
of torque.
NOTE
If the upper air collector section is removed, proceed to step D.
C. If upper air collector section is installed, secure lift sling to lower left air collector
section. Use holes in top flange gussets for sling attachment points.
D. Connect 1-ton (907 kg) capacity overhead hoist to lift fixture or sling. Take up slack on
hoist.
E. Remove bolts and washers that secure two access panels from lower left air collector
section. See figure 4.
4
F. Remove screws that secure frame seal onto lower left air collector section.
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Figure 4. Lower Left Air Collector Section
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G. Remove nuts and bolts that secure lower left air collector section onto CFF forward
flange.
H. Before Service Bulleting LM6000-IND-0258, cut safety wire and remove bolts that
secure lower left air collector section onto CFF aft flange.
I. After Service Bulletin LM6000-IND-0258, cut safety wire and remove bolts and spac-
ers securing lower left air collector section to CFF aft flange.
J. Mark location of lower left air collector flange brackets using marking pen. Remove
nuts and bolts that secure lower left air collector section onto transfer gearbox mount
plate and onto upper air collector section.
K. Loosen bolts that secure support bracket to No. 1 electrical interface panel. Position
support bracket clear of air collector.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
L. Slowly lower hoist while pulling lower left air collector section clear of engine.
M. Remove four bolts and air collector baffle from lower left air collector section.
11. Lower Left Air Collector Section Installation.
A. Install air collector baffle onto lower left air collector section and secure with four
bolts.
NOTE
If the upper air collector section is installed, proceed to step B.
B. Using two bolts, washers, and nuts, if upper air collector section is removed, install air
collector lift fixture, 1C9300, onto lower left air collector section. See figure 1.
Boltheads face up, washers under nuts. Tighten nuts to 420-510 lb in. (47.5-57.6 N·m)
of torque.
NOTE
If the upper air collector section is removed, proceed to step C.
C. If upper air collector section is installed, secure lift sling to lower left air collector
section. Use holes in top flange gussets for sling attachment points.
D. Connect 1-ton (907 kg) capacity overhead hoist to lift fixture or sling.
Change 5 13
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WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
CAUTION
Use care when installing lower air collector section to avoid damaging
frame seals.
E. Carefully position lower left air collector section onto transfer gearbox mount plate
flange. See figure 4.
F. Before Service Bulletin LM6000-IND-0258, apply molybdenum disulfide lubricant
onto threads and washer faces of all nuts and bolts.
G. After Service Bulletin LM6000-IND-0258, apply molybdenum disulfide lubricant to
threads and washer faces of all bolts and nuts, except apply thread lubricant to bolts
used to secure lower left air collector section onto CFF aft flange.
H. Using bolts and nuts, if upper air collector section is installed, secure lower left air
collector section to upper section. Boltheads face up. Tighten nuts finger-tight.
I. Install brackets at positions marked at disassembly. Using bolts and nuts, secure lower
left air collector section and brackets onto transfer gearbox mount plate. Boltheads
face outboard. Tighten nuts finger-tight.
J. Using bolts and nuts, secure lower left air collector section onto CFF forward flange.
Boltheads face aft. Tighten nuts finger-tight.
K. Before Service Bulletin LM6000-IND-0258, using bolts, secure lower left air collector
section onto CFF aft flange. Tighten bolts to 55-70 lb in. (6.3-7.9 N·m) of torque.
Safety-wire bolts.
L. After Service Bulletin LM6000-IND-0258, using bolts and spacers, secure lower
left air collector section onto CFF aft flange. Tighten bolts to 106-124 lb in.
(12.0-14.0 N·m) of torque. Safety-wire bolts.
M. Tighten air collector section flange nuts to 480-570 lb in. (54.2-64.4 N·m) of torque.
Tighten bolts securing support bracket to No. 1 electrical interface panel to 55-70 lb in.
(6.3-7.9 N·m) of torque.
N. Tighten CFF forward flange nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
O. Using screws, secure frame seal onto lower left air collector. Tighten screws to
55-70 lb in. (6.3-7.9 N·m) of torque.
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Figure 5. Transfer Gearbox Mount Plate
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CAUTION
All tools or maintenance items shall be accounted for upon job
completion, or damage to engine could result.
P. Before installing access panels, perform thorough, final inspection for tools or foreign
objects left in air collector.
Q. Using washers and bolts, secure access panels onto lower left air collector section.
Tighten nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
R. Remove air collector lift fixture or lift sling.
S. Remove bottle jack from under transfer gearbox assembly.
12. Transfer Gearbox Mount Plate Removal.
NOTE
• The transfer gearbox mount plate weighs 400 lb (180 kg).
• The transfer gearbox assembly has been removed from the
gearbox mount plate.
A. Remove bolts, washers, and lockwashers that secure access panel to transfer gearbox
mount plate. See figure 5.
B. Support transfer gearbox mount plate using lowering jack, 1C5654.
C. Remove bolts that secure actuator seal.
D. Mark location of CFF forward flange bracket using marking pen. Remove nuts and
bolts that secure transfer gearbox mount plate onto CFF forward flange.
E. Before Service Bulletin LM6000-IND-0258, cut safety wire and remove bolts that
secure transfer gearbox mount plate onto CFF aft flange.
F. After Service Bulletin LM6000-IND-0258, cut safety wire and remove bolts and spac-
ers that secure transfer gearbox mount plate onto CFF aft flange.
G. If lower air collector sections are installed, mark location of flange brackets. Remove
nuts and bolts that secure transfer gearbox mount plate onto lower air collector
sections.
H. Carefully lower jack to remove transfer gearbox mount plate.
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13. Transfer Gearbox Mount Plate Installation.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
A. Using jack, 1C5654, lift transfer gearbox mount plate into position.
B. Before Service Bulletin LM6000-IND-0258, apply molybdenum disulfide lubricant
onto threads and washer faces of all nuts and bolts.
C. After Service Bulletin LM6000-IND-0258, apply molybdenum disulfide lubricant to
threads and washer faces of all bolts and nuts, except apply thread lubricant to bolts
used to secure transfer gearbox mount plate onto CFF aft flange.
D. If lower air collector sections are installed, install flange brackets at positions marked
at disassembly. Using bolts and nuts, secure transfer gearbox mount plate and brackets
onto lower air collector sections. Boltheads face outboard. Tighten nuts finger-tight.
See figure 5.
E. Install CFF forward flange bracket at position marked at disassembly. Using bolts and
nuts, secure transfer gearbox mount plate and bracket onto CFF forward flange.
Boltheads face aft. Tighten nuts finger-tight.
F. Before Service Bulletin LM6000-IND-0258, using bolts, secure transfer gearbox
mount plate onto CFF aft flange. Tighten bolts to 55-70 lb in. (6.3-7.9 N·m) of torque.
Safety-wire bolts.
G. After Service Bulletin LM6000-IND-0258, using bolts and spacers, secure transfer
gearbox mount plate onto CFF aft flange. Tighten bolts to 106-124 lb in. (12.0-14.0
N·m) of torque. Safety-wire bolts.
H. Tighten air collector section flange nuts to 480-570 lb in. (54.3-64.4 N·m) of torque.
I. Tighten CFF forward flange nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
CAUTION
All tools or maintenance items shall be accounted for upon job
completion, or damage to engine could result.
J. Before installing access panel, perform thorough, final inspection for tools or foreign
objects left in air collector.
K. Using washers, lockwashers, and bolts, secure access panel onto transfer gearbox
mount plate. Tighten bolts to 55-70 lb in. (6.3-7.9 N·m) of torque.
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7WP 2411 00
WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR (HPC) UPPER AND
LOWER STATOR CASE REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 18
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 17 ...... 1
18 Blank . . . . . . 1
Alphabetical Index
Subject Page
HPC Lower Stator Case Installation ........................................................................................... 15
HPC Lower Stator Case Removal............................................................................................... 13
HPC Upper Stator Case Installation............................................................................................ 9
HPC Upper Stator Case Removal ............................................................................................... 4
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1. Introduction.
A. This work package contains instructions for removing and installing the high pressure
compressor (HPC) upper and lower stator case.
B. Disconnect and connect electrical leads and connecting tubes between low pressure
compressor (LPC) module and gas turbine per SWP 1913 03.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Stator Vane (VSV) Actuator Components Replace-
ment WP 1410 00
Low Pressure Turbine (LPT) Module External Tubing, Har-
nesses, and Clamping SWP 1913 03
3. Support Equipment.
Nomenclature Part No.
Fixture, HPC Dummy Stator Case 1C9413G01
Retainer, HPC Lower stator Case, 6-12 1C9414G01
Vanes
Jack Assembly, CRF Support 1C9419G01
Fixture, Holding - Variable Stator Arms, 2C6259G05
Stage 3-6
Fixture, Lift - Compressor Stator Case, 2C14699G02
Upper
Tool Set, Alignment - Compressor Horizon- 2C14779G02
tal Flange
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4. Consumable Material.
CAUTION
If thread penetrating oil is used, use Liquid Wrench. Use of other
products could reduce hardware life.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
Marking Pen Sharpie T.E.C.
(Black or Blue)
Penetrating Oil Liquid Wrench (GE Spec. A50TF54)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GP460
5. Expendable Material.
None required.
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6. HPC Upper Stator Case Removal.
A. Disconnect variable stator vane (VSV) actuating mechanism as follows:
(1) Remove VSV hydraulic actuators, actuator brackets, and actuation levers per
WP 1410 00.
(2) Position VSV to full open position (hydraulic actuators extended).
(3) Remove VSV connecting links as follows (figure 1):
(a) Using marking pen, mark stage number on connecting links to be removed.
(b) Remove bolts, washers, and lineup pins from inlet guide vane (IGV) and
stages 1-4 connecting links and remove links from actuation rings. Retain
sleeves, if not damaged, for reinstallation.
(c) Remove bolts from stage 5 connecting links and remove links from actuation
rings. Retain sleeves, if not damaged, for reinstallation.
1
CAUTION
Do not over tighten bolts securing vane holding fixture, 2C6259, or
tool damage will result.
(4) Install vane holding fixture, 2C6259, onto VSV stages 3-5. See figure 2. Secure
with washers and bolts removed in step (3). Tighten bolts only enough to secure
vane holding fixture in place.
2
B. Remove HPC upper stator case as follows:
WARNING
Penetrating oil is toxic to skin, eyes, and respiratory tract. Skin
and eye protection is required. Avoid repeated or prolonged con-
tact. Use in a well-ventilated area.
(1) Apply penetrating oil to forward and aft circumferential flange and
horizontal flange nuts and bolts.
(2) Using marking pen, matchmark brackets to front frame and compressor rear frame
(CRF) flanges.
(3) Position jack, 1C9419, at 6:00 o'clock position on CRF forward flange. Raise jack
enough to support CRF flange, but not enough to exert any upward force.
4 Change 1
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Figure 1. VSV Connecting Links
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Figure 2. Vane Holding Fixture, 2C6259
(4) Remove nuts, bolts, spacers, and brackets that secure HPC upper stator case
forward and aft circumferential flanges.
(5) Install upper compressor stator case lift fixture, 2C14699, as follows (figure 3):
3
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
CAUTION
Ensure compressor vane levers are positioned fully open to prevent
damage to rotor spool.
(a) Using overhead hoist, position upper compressor stator case lift fixture,
2C14699, over upper stator case top vertical centerline.
(b) Turn knurled nut to expand upper compressor stator case lift fixture,
2C14699, until pins engage boltholes in circumferential flanges.
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Figure 3. Upper Compressor Stator Case Lift Fixture, 2C14699
(6) Remove hardware from horizontal flanges, observing the following:
CAUTION
Body-bound bolts shall not be turned, or damage to parts can
result. See figure 4. Do not allow body-bound bolts to turn during
removal.
(a) Remove nuts, spacers, and bolts from horizontal flanges. See figure 4. Use
drift pin and mallet to drive out body-bound bolts.
4
(b) If horizontal flange bolt or nut is loose, broken, or missing, replace that bolt
and nut, plus bolt and nut on each side.
(c) If more than five horizontal flange bolts or nuts are loose, broken, or missing,
replace all bolts and nuts in both horizontal flanges.
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Figure 4. HPC High-Boss Case Horizontal Flange Hardware
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WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
(7) Using overhead hoist, lift upper stator case from engine.
(8) Place stator case on clean work surface and remove upper compressor stator case
lift fixture, 2C14699, and vane holding fixture, 2C6259.
7. HPC Upper Stator Case Installation.
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
A. Using a clean cloth moistened with isopropyl alcohol, clean horizontal flange contact
faces of upper and lower stator cases.
CAUTION
Do not over tighten bolts securing vane holding fixture,
2C6259, or tool damage will result.
B. Install vane holding fixture, 2C6259, onto VSV stages 3-5. See figure 2. Secure with
washers and bolts. Tighten bolts only enough to secure vane holding fixture in place.
C. Install upper compressor stator case lift fixture, 2C14699, as follows figure 3:
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
(1) Using overhead hoist, position upper compressor stator case lift fixture, 2C14699,
over upper stator case top vertical centerline.
(2) Turn knurled nut to expand upper compressor stator case lift fixture, 2C14699,
until pins engage boltholes in circumferential flanges.
(3) Inspect HPC rotor for FOD.
D. Use overhead hoist to position upper stator case over compressor rotor.
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CAUTION
Ensure compressor vane levers are positioned fully open to prevent
damage to rotor spool.
E. Carefully lower stator case into position. Remove upper compressor stator case lift
fixture, 2C14699, and vane holding fixture, 2C6259.
F. Install brackets, bolts, and nuts at aft circumferential flange. Install hardware at
locations marked during disassembly. Do not tighten nuts at this time.
G. Apply thread lubricant to threads of forward circumferential flange.
H. Install hardware at locations marked during disassembly. Do not tighten bolts at this
time.
I. Install horizontal flange retaining hardware as follows:
(1) Apply thread lubricant to threads and washer faces of horizontal flange attaching
bolts.
(2) Inspect to ensure flanges are in contact on both sides over full length of case. If
required, install clamps or bolts at forward and aft ends and tighten slightly to pull
flanges together. Do not overtighten clamps on bolts so that alignment pins cannot
function. Do not remove clamps or bolts until assembly bolts are installed and
tightened to final torque.
NOTE
Bolt positions on the horizontal flanges are counted from the aft
flange forward.
(3) Counting from aft end on both sides, install body-bound bolts or alignment pins
from alignment tool set, 2C14779, in horizontal flange bolthole locations 2, 5, 9,
21, 25, 31, and 35. See figure 4.
(4) Ensure body-bound bolts or alignment pins are fully seated. While restraining pins
with Allen wrench, tighten nuts on small diameter pins to 40 lb in. (4.5 N·m) of
torque. Use socket from alignment tool set, 2C14779, to enable access in tight
clearance areas. Avoid side loads.
(5) While restraining pins with Allen wrench, tighten nuts on large diameter pins to
240 lb in. (27.1 N·m) of torque.
(6) Install bolts, spacers, and nuts into remaining horizontal flange boltholes per
figure 4.
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NOTE
For ease of assembly, it is permitted to advance up to four bolts farther
along one horizontal flange than the other.
(7) Tighten nuts, in sequence, starting from the aft end and alternating from flange to
flange. Torque nuts per figure 4.
(8) Remove alignment pins and replace with body-bound bolts, spacers, and nuts per
figure 4.
(9) Tighten nuts, in sequence, starting from aft end and alternating from flange to
flange. Torque nuts per figure 4.
(10) Retighten horizontal flange bolts with spacers, starting from aft end and
alternating from flange to flange. Do not unseat nuts during retightening.
J. Tighten aft circumferential flange nuts to 380-420 lb in. (42.9-47.5 N·m) of torque.
Tightening sequence is as follows:
(1) Tighten four bolts from horizontal flange.
(2) Tighten four bolts from top vertical centerline.
(3) Continue tightening aft circumferential flange bolts, alternating from side to side,
until all nuts are tightened.
K. Tighten forward circumferential flange bolts per figure 5. Safety-wire bolts in groups
of two or three.
5
L. Remove jack, 1C9419.
M. Connect VSV actuating mechanism as follows:
(1) Remove vane holding fixture, 2C6259, from VSV stages 3-5.
(2) Install connecting links as follows:
(a) Loosen self-locking nuts that secure first five vane arms at each end of upper
and lower stage 5 actuator rings. Loosen self-locking nut until flush with end
of vane stem.
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Figure 5. Forward Circumferential Flange Bolt Installation
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CAUTION
Connecting links shall be installed on correct stage and with lever
arm pins engaging sleeves, or VSV off-schedule operation and
engine damage may result.
(b) Install sleeves into connecting link ID. Ensure connecting link is correct for
stage being installed.
(c) Position connecting link onto actuation rings, ensuring FWD marking faces
forward. Install IGV and stages 1-4 lineup pins, ensuring lever arm pins
engage sleeves.
(d) Install bolts and washers on IGV and stages 1-4. Install bolts on stage 5.
Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety-wire.
(e) Ensure all lever arm pins are engaged in sleeves and are not engaged with
connecting link lightening holes.
CAUTION
Stage 5 vane stem self-locking nuts loosened in step (a) shall be
retorqued, or damage to engine will occur.
(f) Tighten self-locking nuts loosened in step (a) to 50-70 lb in. (5.6-7.9 N·m) of
torque.
(3) Install VSV hydraulic actuators, actuator brackets, and actuation levers per
WP 1410 00.
8. HPC Lower Stator Case Removal.
CAUTION
Do not remove HPC lower stator case unless the upper stator case
or dummy case is installed in the lower position.
A. Remove HPC upper stator case per paragraph 6.
B. Install stator case retainer, 1C9414, to HPC lower stator case as follows:
NOTE
The HPC stator case retainer retains the stator vanes in the lower
case half as the case is rotated to the 12:00 o'clock position.
(1) Install retainer with bend outboard and down, with aft edge against CRF.
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CAUTION
Do not over tighten knobs securing retainer, or tool damage will
result.
(2) Align retainer studs through their respective boltholes along horizontal flange.
Secure with knurled knobs from bottom side of flange. Tighten knobs only
enough to secure retainer in place.
(3) Repeat steps (1) and (2) for the other retainer and flange.
C. Install upper stator case or dummy stator case, 1C9413, and secure with nuts and bolts
in boltholes 4, 8, 12, and 16. Install nut and bolt in bolthole 34 of case. Tighten nuts to
210-230 lb in. (23.7-26.0 N·m) of torque.
D. Rotate HPC lower stator case to top position as follows:
WARNING
Penetrating oil is toxic to skin, eyes, and respiratory tract. Skin
and eye protection is required. Avoid repeated or prolonged con-
tact. Use in a well-ventilated area.
(1) Apply penetrating oil to forward and aft circumferential flange and
horizontal flange nuts and bolts.
(2) Using marking pen, matchmark brackets to front frame and CRF flanges.
(3) Remove nuts, bolts, spacers, and brackets that secure stator case forward and aft
circumferential flanges.
(4) Rotate stator cases so lower case is on top.
(5) Install bolts and nuts to secure upper stator case or dummy stator case, 1C9413, to
lower portion of forward and aft circumferential flanges. Tighten bolts and nuts to
210-230 lb in. (23.7-26.0 N·m) of torque.
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E. Remove HPC lower stator case as follows:
(1) Install upper compressor stator case lift fixture, 2C14699, as follows (figure 3):
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
CAUTION
Ensure compressor vane levers are positioned fully open to prevent
damage to rotor spool.
(a) Use overhead hoist to position upper compressor stator case lift fixture,
2C14699, over lower stator case top vertical centerline.
(b) Turn knurled nut to expand upper compressor stator case lift fixture,
2C14699, until pins engage boltholes in circumferential flanges.
(2) Lift lower stator case from engine using overhead hoist.
(3) Place stator case on clean work surface and remove tooling.
9. HPC Lower Stator Case Installation.
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
A. Using a clean cloth moistened with isopropyl alcohol, clean horizontal flange contact
faces of upper and lower stator cases.
CAUTION
Do not over tighten bolts securing vane holding fixture, 2C6259, or
tool damage will result.
B. Install vane holding fixture, 2C6259, on VSV stages 3-5. See figure 2. Secure using
washers and bolts. Tighten bolts only enough to secure vane holding fixture in place.
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C. Install stator case retainer, 1C9414, to HPC lower stator case as follows:
NOTE
The HPC stator case retainer retains the stator vanes in the lower
case half as the case is rotated to the 12:00 o'clock position.
(1) Install retainer with bend outboard and down, with aft edge against CRF.
CAUTION
Do not over tighten knobs securing retainer, or tool damage will
result.
(2) Align retainer studs through their respective boltholes along horizontal flange.
Secure with knurled knobs from bottom side of flange. Tighten knobs only
enough to secure retainer in place.
(3) Repeat steps (1) and (2) for the other retainer and flange.
(4) Inspect HPC rotor for FOD.
D. Install lift fixture, 2C14699, as follows figure 3:
(1) Use overhead hoist to position lower stator case over compressor rotor.
(2) Turn knurled nut to expand upper compressor stator case lift fixture, 2C14699,
until pins engage boltholes in circumferential flanges.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
E. Use overhead hoist to position lower stator case over compressor rotor.
CAUTION
Ensure compressor vane levers are positioned fully open to prevent
damage to rotor spool.
F. Carefully lower the stator case into position. Remove upper compressor stator case lift
fixture, 2C14699.
G. Install nuts and bolts in horizontal flange boltholes 4, 8, 12, and 16. Install nut and bolt
into bolthole 34 of case. Tighten nuts to 210-230 lb in. (23.7-26.0 N·m).
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H. Rotate stator cases as follows:
(1) Remove nuts and bolts that secure the upper stator case or dummy case onto
lower portion of forward and aft circumferential flanges.
(2) Rotate stator cases so that lower case is at bottom position.
I. Apply thread lubricant to threads of forward circumferential flange attaching bolts.
J. Install brackets, bolts, and nuts to lower case forward and aft circumferential flanges.
Install hardware at locations marked during disassembly. Do not tighten bolts or nuts
at this time.
K. Remove nuts and bolts from horizontal flanges.
L. Remove screws that secure stator case retainer, 1C9414, onto lower stator case
horizontal flange. Remove retainer, 1C9414, from between stator case horizontal
flanges.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
M. If dummy stator case, 1C9413, is installed, remove using overhead hoist.
N. Install upper stator case per paragraph 7.
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7SWP 2411 01
SUBORDINATE WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR UPPER/LOWER
STATOR CASE OPENING/CLOSING
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 30
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 30 ...... 1
Alphabetical Index
Subject Page
High Pressure Compressor Lower Stator Case Closing.............................................................. 26
High Pressure Compressor Lower Stator Case Opening ............................................................ 21
High Pressure Compressor Upper Stator Case Closing .............................................................. 14
High Pressure Compressor Upper Stator Case Opening............................................................. 4
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1. Introduction.
A. This subordinate work package (SWP) contains instructions for installation and removal of
the fixture set to raise and hinge the high pressure compressor (HPC) upper stator case.
B. Disconnect electrical leads and connecting tubes between low pressure compressor (LPC)
module and gas turbine per SWP 1913 02.
C. A shim set is provided which allows the lower case to be rotated 180 degrees about
horizontal axis to position the lower case at the top.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Stator Vane (VSV) Actuator Components Replace- WP 1410 00
ment
Gas/Steam Fuel System Components Replacement WP 1510 00
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
3. Support Equipment.
Nomenclature Part No.
Jack Assembly, CRF Support 1C9376G01/G02
Fixture Set, Raise & Hinge - Upper Com- 1C9400G01
pressor Case
Fixture, Holding - Variable Stator Arms, 2C6259G05
Stage 3-6
Tool Set, Alignment - Compressor Horizon- 2C14779G02
tal Flange
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4. Consumable Material.
CAUTION
If thread penetrating oil is used, use Liquid Wrench. Use of
other products could reduce hardware life.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
Marking Pen Sharpie T.E.C.
(Black or Blue)
Penetrating Oil Liquid Wrench (GE Spec. A50TF54)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GP460
5. Expendable Material.
None required.
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6. High Pressure Compressor Upper Stator Case Opening.
A. Disconnect variable stator vane (VSV) actuating mechanism as follows:
(1) Position VSVs to full open position (hydraulic actuators extended).
(2) Remove piping, as required, per SWP 1913 02.
(3) Remove upper fuel manifold sections per WP 1510 00.
(4) Remove VSV hydraulic actuators, actuator brackets, and actuation levers per
WP 1410 00.
(5) Remove VSV connecting links as follows (figure 1):
(a) Mark stage number on connecting links to be removed with marking pen.
(b) Remove bolts, washers, and lineup pins from stages IGV and 1-4 connecting
links and remove links from actuation rings. Retain sleeves, if not damaged,
for reinstallation.
(c) Remove bolts from stage 5 connecting links and remove links from actuation
rings. Retain sleeves, if not damaged, for reinstallation.
1
CAUTION
Do not over tighten bolts securing vane holding fixture, 2C6259, or
tool damage will result.
(6) Install holding fixture, 2C6259, onto VSV stages 3-5. See figure 2. Using bolts
removed in step (5), secure fixture to stages. Tighten bolts only enough to secure
fixture in place.
2
B. Open HPC upper stator case as follows:
WARNING
Penetrating oil is toxic to skin, eyes, and respiratory tract. Skin
and eye protection is required. Avoid repeated or prolonged con-
tact. Use in a well-ventilated area.
(1) Apply penetrating oil to forward and aft circumferential flange and
horizontal flange nuts and bolts.
(2) Using marking pen, matchmark brackets to front frame (figure 3) and compressor
rear frame (CRF) (figure 4) flanges.
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Figure 1. VSV Connecting Links
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Figure 2. VSV Vane Holding Set Secure Fixture, 2C6259
3
Figure 3. Forward Circumferential Flange Bolt Locations
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4
Figure 4. Aft Circumferential Flange Bolt Locations
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5
Figure 5. Compressor Case Orientation
(3) Position jack assembly, 1C9376, at 6:00 o'clock position on CRF forward flange.
Raise jack just enough to support CRF flange, but not enough to exert any upward
force. See figure 5.
(4) Remove nuts, bolts, spacers, and brackets that secure HPC upper stator case
forward and aft circumferential flanges, figures 3 and 4.
CAUTION
• Ensure compressor vane levers are positioned fully open to prevent
damage to rotor spool.
• Body-bound bolts shall not be turned, or damage to parts can
result. See figure 6. Do not allow body-bound bolts to turn during
removal.
(5) Remove hardware from horizontal flanges, observing the following:
(a) Remove nuts, spacers, and bolts from horizontal flanges. See figure 6. Use a
drift pin and mallet to drive out body-bound bolts.
6
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Figure 6. HPC High-Boss Case Horizontal Flange Hardware
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(b) If horizontal flange bolt or nut is loose, broken, or missing, record location
and replace bolt and nut plus bolt and nut on each side.
(c) If more than five horizontal bolts or nuts are loose, broken, or missing,
replace all bolts and nuts in both horizontal flanges.
(6) Install aft jack, 1C9400P17, and forward jacks, 1C9400P18 and 1C9400P19, as
follows:
(a) For forward jacks, 1C9400P18 and 1C9400P19, remove second and fourth
bolts from forward HPC stator case to fan frame flange, counting down from
horizontal splitline, figure 3.
(b) Align lower tabs on forward jacks, 1C9400P18 and 1C9400P19, with flange
connecting forward HPC stator case to fan frame flange, figure 7.
7
(c) For aft jack, 1C9400P17, remove second bolt and nut from flange connecting
HPC stator case to CRF, figure 4.
(d) Align lower tabs on aft jack, 1C9400P17, to straddle HPC stator case/CRF
flange, figure 7.
(e) Extend threaded rod on each jack so that arm aligns with second hole in
flange. Insert pin until upper arm is flush against engine flange.
(f) For aft jack, 1C9400P17, fit lower tabs over aft flange and bolt into place.
(g) For forward jacks, 1C9400P18 and 1C9400P19, fit lower tabs against HPC
stator case forward flange and bolt into place on fan frame. Secure with two
bolts on each side.
(7) Extend each jack until resistance is felt. Using four operators, turn each nut, in
unison, approximately 1/4 turn each time until HPC stator case is raised
approximately 1 inch (25.4 mm) for installing hinges.
(8) Install hinges and lift bar as follows (figure 7):
(a) Align forward, upper and lower hinges, 1C9400P05 and 1C9400P06, onto
horizontal flange of HPC stator case, right side, aft looking forward. Position
hinges so forward hole in hinge aligns with second hole from forward end of
upper HPC stator case.
(b) Using three 1/4-inch fasteners, secure forward hinges to HPC stator case.
(c) Align aft, upper and lower hinges, 1C9400P07 and 1C9400P08, from fixture
set, 1C9400, onto horizontal flange of HPC stator case, right side, aft looking
forward. Position hinges so aft hole in hinge aligns with sixth hole from aft
end of HPC stator case.
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Figure 7. Use of Jacks, Hinges, and Lift Bar from Fixture Set, 1C9400 (Sheet 1 of 3)
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Figure 7. Use of Jacks, Hinges, and Lift Bar from Fixture Set, 1C9400 (Sheet 2 of 3)
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Figure 7. Use of Jacks, Hinges, and Lift Bar from Fixture Set, 1C9400 (Sheet 3 of 3)
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(d) Using two 3/8-inch and two 7/16-inch fasteners, secure aft hinges onto HPC
stator case.
(e) Using three 1/4-inch fasteners, secure forward handle, 1C9400P03, onto
underside of left side of horizontal flange of HPC stator case, aft looking
forward.
(f) Using two 3/8-inch and two 7/16-inch fasteners, secure aft handle,
1C9400P04, onto underside of left side of horizontal flange of HPC stator
case, aft looking forward.
(9) Ensure upper HPC stator case is supported by hinges and lift bar assembly.
Remove jacks.
(10) Install strut into position as follows (figure 7):
(a) Raise upper HPC stator case by lifting up on lift bar (two man operation).
Open to height desired.
(b) Install top end of strut over aft flange of HPC stator case. Align strut holes
over fourth hole CW from the horizontal flanges holes, aft looking forward.
(c) Insert ball-lock pin through holes in strut and flange.
(d) Install bottom end of strut over forward flange of CRF. Align strut over third
hole CCW from top vertical centerline, aft looking forward. Insert ball-lock
pin.
7. High Pressure Compressor Upper Stator Case Closing.
A. Inspect HPC rotor for FOD.
B. Lower HPC upper stator case as follows:
(1) Install jacks, 1C9400P17, 1C9400P18, and 1C9400P19, as follows (figure 7):
(a) For forward jacks, 1C9400P18 and 1C9400P19, remove second and fourth
bolts from flange connecting forward HPC stator case to fan frame, counting
from splitline, figure 3.
(b) Align lower tabs on forward jacks, 1C9400P18 and 1C9400P19, with flange
connecting forward HPC stator case to fan frame, figure 7.
(c) For aft jack, 1C9400P17, remove second bolt and nut from flange connecting
HPC stator case to CRF, figure 4.
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(d) Align lower tabs on aft jack, 1C9400P17, to straddle HPC stator case/CRF
flange, figure 7.
(e) Extend threaded rod on each jack so that arm aligns with second hole in
flange. Insert pin until upper arm is flush against engine flange.
(f) For aft jack, 1C9400P17, fit the lower tabs over aft flange and bolt into place.
(g) For forward jacks, 1C9400P18 and 1C9400P19, fit the lower tabs against
HPC stator case forward flange and bolt into place on fan frame. Secure with
two bolts on each side.
(h) Extend each jack approximately 1 inch (25.4 mm).
(2) Remove struts as follows (figure 7):
(a) While two people hold HPC stator case to keep it from falling, remove
ball-lock pins that secure struts to upper HPC stator case.
(b) Disconnect struts from the lower HPC stator case.
(c) Lower upper HPC stator case until it rests on jacks, 1C9400P17, 1C9400P18,
and 1C9400P19.
(3) Remove lift bar and hinges as follows (figure 7):
(a) Remove two 3/8-inch and two 7/16-inch fasteners that secure aft handle,
1C9400P04, onto horizontal flange of HPC stator case. Remove handle.
(b) Remove three 1/4-inch fasteners that secure forward handle, 1C9400P03,
onto horizontal flange of HPC stator case. Remove handle.
(c) Remove two 3/8-inch and two 7/16-inch fasteners that secure aft hinge onto
horizontal flange of HPC stator case. Remove hinge.
(d) Remove three 1/4-inch fasteners that secure forward hinge onto horizontal
flange of HPC stator case. Remove hinge.
(4) Turn jacks, 1C9400P17, 1C9400P18, and 1C9400P19, in unison and lower upper
HPC stator case down to fit onto lower HPC stator case.
(5) Remove jacks, 1C9400P17, 1C9400P18, and 1C9400P19.
(6) Clean and store all tools from fixture set, 1C9400, in container, 1C9400P02.
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WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
C. Using clean cloth moistened with Isopropyl alcohol, clean horizontal flange contact
faces of upper and lower stator cases.
CAUTION
Do not over tighten bolts securing vane holding fixture, 2C6259, or
tool damage will result.
D. Install vane holding set secure fixture, 2C6259, onto VSV stages 3-5. See figure 2.
Secure with washers and bolts. Tighten bolts only enough to secure vane holding
fixture in place.
CAUTION
Ensure compressor vane levers are positioned fully open to prevent
damage to rotor spool.
E. Install brackets, bolts, and nuts at aft circumferential flange. Install hardware at
locations marked during disassembly. Do not tighten nuts at this time.
F. Apply thread lubricant to threads of forward circumferential flange attaching bolts.
G. Install brackets and bolts at forward circumferential flange. Install hardware at
locations marked during disassembly. Do not tighten bolts at this time.
H. Install horizontal flange retaining hardware as follows:
(1) Apply thread lubricant to threads and washer faces of horizontal flange attaching
bolts. See figure 6.
(2) Ensure flanges are in contact on both sides over their full length. If required,
install clamps or bolts at forward and aft ends and tighten slightly to pull flanges
together. Do not overtighten clamps or bolts so that alignment pins cannot
function. Do not remove these clamps or bolts until assembly bolts are installed
and tightened to final torque.
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NOTE
Bolt positions on the horizontal flanges are counted from the aft
flange forward.
(3) Install body-bound bolts or alignment pins from tool set, 2C14779, in horizontal
flange bolthole locations 2, 5, 9, 21, 25, 31, and 35, counting from aft end on both
sides. See figure 6.
(4) Ensure that body-bound bolts or alignment pins are fully seated. Restrain pins
using Allen wrench and tighten nuts on small diameter pins to 40 lb in. (4.5 N·m)
of torque. Use socket from tool set, 2C14779, to enable access in tight clearance
areas. Avoid side loads.
(5) Using Allen wrench, restrain pins, and tighten nuts on large diameter pins to
240 lb in. (27.1 N·m) of torque.
(6) Install bolts, spacers, and nuts in remaining horizontal flange boltholes per
figure 6.
(7) Tighten nuts, in sequence, starting from aft end and alternating from flange to
flange. For ease of assembly, it is permitted to advance up to four bolts farther
along one horizontal flange than the other. Tighten nuts to torque values listed in
figure 6.
(8) Remove alignment pins and replace with body-bound bolts, spacers, and nuts per
figure 6.
(9) Tighten nuts, in sequence, starting from aft end and alternating from flange to
flange. Tighten nuts to torque values listed in figure 6.
(10) Tighten horizontal flange bolts with spacers, starting from aft end and alternating
from flange to flange. Do not unseat nuts during retightening.
I. Tighten aft circumferential flange nuts to 380-420 lb in. (42.9-47.5 N·m) of torque.
Tightening sequence is as follows:
(1) Tighten four bolts from horizontal flange.
(2) Tighten four bolts from top vertical centerline.
(3) Continue tightening aft circumferential flange bolts, alternating from side to side,
until all nuts are tightened, figure 8.
8
J. Tighten forward circumferential flange bolts to torque values listed in figure 9.
Safety-wire bolts in groups of two or three.
9
K. Remove jack assembly, 1C9376.
Change 1 17
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Figure 8. Aft Circumferential Flange Bolt Installation
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Figure 9. Forward Circumferential Flange Bolt Installation
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L. Connect VSV actuating mechanism as follows:
(1) Remove vane holding fixture, 2C6259, from VSV stages 3-5.
(2) Install connecting links as follows (figure 1):
(a) Loosen self-locking nuts that secure first five vane arms at each end of upper
and lower stage 5 actuator rings. Loosen self-locking nut until flush with end
of vane stem.
CAUTION
Connecting links shall be installed on correct stage and with lever
arm pins engaging sleeves, or VSV off-schedule operation and
engine damage may result.
(b) Install sleeves into connecting link ID. Ensure connecting link is correct for
stage being installed.
(c) Position connecting link onto actuation rings, ensuring FWD marking faces
forward. Install IGV and stages 1-4 lineup pins, ensuring lever arm pins
engage sleeves.
(d) Install bolts and washers onto IGV and stages 1-4. Install bolts onto stage 5.
Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety-wire.
(e) Ensure all lever arm pins are engaged in sleeves and are not engaged with
connecting link lightening holes.
CAUTION
Stage 5 vane stem self-locking nuts loosened in substep (a)
shall be retorqued, or damage to engine will occur.
(f) Tighten self-locking nuts loosened in substep (a) to 50-70 lb in. (5.6-7.9 N·m)
of torque.
(3) Install VSV hydraulic actuators, actuator brackets, and actuation levers per
WP 1410 00.
(4) Install upper fuel manifold sections per WP 1510 00.
(5) Install piping per SWP 1913 02.
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8. High Pressure Compressor Lower Stator Case Opening.
A. Disconnect VSV actuating mechanism as follows:
(1) Position VSVs to full open position (hydraulic actuators extended).
(2) Remove piping, as needed, per SWP 1913 02.
(3) Remove VSV hydraulic actuators, actuator brackets, and actuation levers per
WP 1410 00.
(4) Remove VSV connecting links as follows (figure 1):
(a) Mark stage number on connecting links to be removed with marking pen.
(b) Remove bolts, washers, and lineup pins from stages IGV and 1-4 connecting
links and remove links from actuation rings. Retain sleeves, if not damaged,
for reinstallation.
(c) Remove bolts from stage 5 connecting links and remove links from actuation
rings. Retain sleeves, if not damaged, for reinstallation.
CAUTION
Do not over tighten bolts securing vane holding fixture, 2C6259, or
tool damage will result.
(5) Install vane holding fixture, 2C6259, onto VSV stages 3-5. See figure 2. Using
bolts removed in step (4), secure fixtures to stages. Tighten bolts only enough to
secure fixtures in place.
B. Open HPC lower stator case as follows:
WARNING
Penetrating oil is toxic to skin, eyes, and respiratory tract. Skin
and eye protection is required. Avoid repeated or prolonged con-
tact. Use in a well-ventilated area.
(1) Apply penetrating oil to forward and aft circumferential flange and
horizontal flange nuts and bolts.
(2) Using marking pen, matchmark brackets to front frame, figure 3, and CRF
(figure 4) flanges.
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(3) Position jack assembly, 1C9376, at 6:00 o'clock position on CRF forward flange.
Raise jack just enough to support CRF flange, but not enough to exert any upward
force (figure 5)
(4) Remove nuts, bolts, spacers, and brackets that secure HPC upper stator case
forward and aft circumferential flanges (figures 3 and 4).
CAUTION
• Ensure compressor vane levers are positioned fully open
to prevent damage to rotor spool.
• Body-bound bolts shall not be turned, or damage to parts
can result. See figure 6. Do not allow body-bound bolts to
turn during removal.
(5) Remove hardware from horizontal flanges, observing the following:
(a) Remove nuts, spacers, and bolts from horizontal flanges. See figure 6. Use
drift pin and mallet to drive out body-bound bolts.
(b) If horizontal flange bolt or nut is loose, broken, or missing, record location
and replace bolt and nut plus bolt and nut on each side.
(c) If more than five horizontal bolts or nuts are loose, broken, or missing,
replace all bolts and nuts in both horizontal flanges.
(6) Install aft jack, 1C9400P17, and forward jacks, 1C9400P18 and 1C9400P19, as
follows:
(a) For forward jacks, 1C9400P18 and 1C9400P19, remove second and fourth
bolts from flange connecting forward HPC stator case to fan frame, counting
from splitline (figure 3).
(b) Align lower tabs on forward jacks, 1C9400P18 and 1C9400P19, with flange
connecting forward HPC stator case to fan frame (figure 7).
(c) For aft jacks, 1C9400P17, remove second bolt and nut from flange
connecting HPC stator case to CRF (figure 4).
(d) Align lower tabs on aft jacks, 1C9400P17, to straddle HPC stator case/CRF
flange (figure 7).
(e) Extend threaded rod on each jack so that arm aligns with second hole in
flange. Insert pin until upper arm is flush against engine flange.
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(f) For aft jacks, 1C9400P17, fit lower tabs over aft flange and bolt into place.
(g) For forward jacks, 1C9400P18 and 1C9400P19, fit lower tabs against HPC
stator case forward flange and bolt into place on fan frame. Secure with two
bolts on each side.
(7) Extend each jack until resistance is felt. Using four operators, turn each nut, in
unison, approximately 1/4 turn each time until HPC stator case is raised
approximately 1 inch (25.4 mm) for installing hinges.
(8) Install aft shims, 1C9400P11 and 1C9400P23, as follows (figure 7):
(a) Align aft shim, 1C9400P11, onto right side horizontal flange. Insert studs
into the second and thirteenth holes from aft end of HPC stator case. Install
stud through horizontal flange of lower case and secure finger-tight at under
side of flange.
(b) Align aft shim, 1C9400P23, onto left side horizontal flange. Insert studs into
the second and thirteenth holes from aft end of HPC stator case. Install stud
through horizontal flange of lower case and secure finger-tight at under side
of flange.
(9) Install forward shims, 1C9400P10 and 1C9400P22, as follows (figure 7):
(a) Align forward shim, 1C9400P10, onto right side horizontal flange. Position
shim so forward most hole in shim aligns with third flange hole from forward
end of HPC stator case.
(b) Align forward shim, 1C9400P22, onto left side horizontal flange. Position
shim so forward most hole in shim aligns with third flange hole from forward
end of HPC stator case.
(10) Using jacks, 1C9400P17, 1C9400P18, and 1C9400P19, lower upper HPC stator
case down onto lower compressor case.
(11) Remove jacks, 1C9400P17, 1C9400P18, and 1C9400P19.
(12) Bolt HPC stator case halves together as follows:
CAUTION
Ensure compressor vane levers are positioned fully open to
prevent damage to rotor spool.
(a) Install bolts and nuts at aft circumferential flange. Do not tighten nuts at this
time.
(b) Install bolts at forward circumferential flange. Do not tighten bolts at this
time.
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(c) Install horizontal flange retaining hardware as follows:
(d) Ensure flanges are in contact on both sides over their full length. If required,
install clamps or bolts at forward and aft ends and tighten slightly to pull
flanges together. Do not overtighten clamps or bolts so that alignment pins
cannot function. Do not remove these clamps or bolts until assembly bolts are
installed and tightened to final torque. See figure 6.
NOTE
Bolt positions on the horizontal flanges are counted from the aft
flange forward.
(e) Install body-bound bolts or alignment pins from tool set, 2C14779, in
horizontal flange bolthole locations 2, 5, 9, 21, 25, 31, and 35, counting from
aft end on both sides. See figure 6.
(f) Ensure that body-bound bolts or alignment pins are fully seated. Using Allen
wrench, restrain pins, and tighten nuts on small diameter pins to 40 lb in.
(4.5 N·m) of torque. Use socket from tool set, 2C14779, to enable access in
tight clearance areas. Avoid side loads.
(g) Using Allen wrench, restrain pins, and tighten nuts on large diameter pins to
240 lb in. (27.1 N·m) of torque.
(h) Install bolts, spacers, and nuts in remaining horizontal flange boltholes per
figure 6.
(i) Tighten nuts, in sequence, starting from aft end and alternating from flange to
flange. For ease of assembly, it is permitted to advance up to four bolts farther
along one horizontal flange than the other. Tighten nuts to torque values
listed in figure 6.
(j) Remove alignment pins and replace with body-bound bolts, spacers, and nuts
per figure 6.
(k) Tighten nuts, in sequence, starting from aft end and alternating from flange to
flange. Tighten nuts to torque values listed in figure 6.
(l) Tighten horizontal flange bolts with spacers, starting from aft end and
alternating from flange to flange. Do not unseat nuts during retightening.
(m) Tighten aft circumferential flange nuts to 380-420 lb in. (42.9-47.5 N·m) of
torque. Tightening sequence is as follows (figure 8):
1 Tighten four bolts from horizontal flange.
2 Tighten four bolts from top vertical centerline.
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3 Continue tightening aft circumferential flange bolts, alternating from side
to side, until all nuts are tightened.
(n) Tighten forward circumferential flange bolts to torque values listed in
figure 9.
(13) Rotate HPC stator casing so lower half is on top.
(14) Install jacks, 1C9400P17, 1C9400P18, and 1C9400P19, per step (5).
(15) Extend each jack until resistance is felt. Using four operators, turn each nut, in
unison, approximately 1/4 turn each time until HPC stator case is raised
approximately 1 inch (25.4 mm) for installing hinges.
(16) Install hinges and lift bar as follows (figure 7):
(a) Align forward, upper and lower hinges, 1C9400P05 and 1C9400P06, onto
horizontal flange of HPC stator case, right side, aft looking forward. Position
hinges so forward hole in hinge aligns with the second hole from forward end
of upper HPC stator case.
(b) Using three 1/4-inch fasteners, secure forward hinges to case.
(c) Align aft, upper and lower hinges, 1C9400P07 and 1C9400P08, onto
horizontal flange of HPC stator case, right side, aft looking forward. Position
hinges so aft hole in hinge aligns with sixth hole from aft end of the case.
(d) Using two 3/8-inch and two 7/16-inch fasteners, secure aft hinges to HPC
stator case.
(e) Using three 1/4-inch fasteners, secure forward handle, 1C9400P03, onto
underside of left side of horizontal flange of HPC stator case, aft looking
forward.
(f) Using two 3/8-inch and two 7/16-inch fasteners, secure aft handle,
1C9400P04, onto underside of left side of horizontal flange of HPC stator
case, aft looking forward.
(17) Ensure case is supported by hinges and lift bar assembly. Remove jacks,
1C9400P17, 1C9400P18, and 1C9400P19.
(18) Install strut into position as follows (figure 7):
(a) Raise upper HPC stator case by lifting up on lift bar (two man operation).
Open to height desired.
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(b) Install top end of strut over aft flange of HPC stator case. Align strut holes
over fourth hole CW from the horizontal flanges holes, aft looking forward.
(c) Insert ball-lock pin through holes in strut and flange.
(d) Install bottom end of strut over forward flange of CRF. Align strut over third
hole CCW from top vertical centerline, aft looking forward. Insert ball-lock
pin.
9. High Pressure Compressor Lower Stator Case Closing.
WARNING
Deleted.
A. Inspect HPC rotor for FOD.
B. Lower HPC stator case as follows:
(1) Install jacks, 1C9400P17, 1C9400P18, and 1C9400P19, as follows:
(a) For forward jacks, 1C9400P18 and 1C9400P19, remove second and fourth
bolts from flange connecting forward HPC stator case to fan frame, counting
from splitline (figure 3).
(b) Align lower tabs on forward jacks, 1C9400P18 and 1C9400P19, with flange
connecting forward HPC stator case to fan frame (figure 7).
(c) For aft jack, 1C9400P17, remove second bolt and nut from flange connecting
HPC stator case to CRF (figure 4).
(d) Align lower tabs on aft jack, 1C9400P17, to straddle HPC stator case/CRF
flange (figure 7).
(e) Extend threaded rod on each jack so that arm aligns with second hole in
flange. Insert pin until upper arm is flush against engine flange.
(f) For aft jack, 1C9400P17, fit the lower tabs over aft flange and bolt into place.
(g) For forward jacks, 1C9400P18 and 1C9400P19, fit the lower tabs against
HPC stator case forward flange and bolt into place on fan frame. Secure with
two bolts on each side.
(h) Extend each jack approximately 1 inch (25.4 mm).
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(2) Remove struts as follows (figure 7):
(a) While two people hold HPC stator case to keep it from falling, remove
ball-lock pins that secure struts to upper HPC stator case.
(b) Disconnect struts from lower HPC stator case.
(c) Lower upper HPC stator case until it rests on jacks, 1C9400P17, 1C9400P18,
and 1C9400P19.
(3) Remove lift bar and hinges as follows (figure 7):
(a) Remove two 3/8-inch and two 7/16-inch fasteners that secure aft handle,
1C9400P04, onto horizontal flange of HPC stator case. Remove handle.
(b) Remove three 1/4-inch fasteners that secure forward handle, 1C9400P03,
onto horizontal flange of HPC stator case. Remove handle.
(c) Remove two 3/8-inch and two 7/16-inch fasteners that secure aft hinge onto
horizontal flange of HPC stator case. Remove hinge.
(d) Remove three 1/4-inch fasteners that secure forward hinge onto horizontal
flange of HPC stator case. Remove hinge.
(4) Remove shims as follows (figure 7):
(a) Remove studs and remove aft shims, 1C9400P11 and 1C9400P23, from aft
end of HPC stator case.
(b) Remove studs and remove forward shims, 1C9400P10 and 1C9400P22, from
forward end of HPC stator case.
(5) Turn jacks, 1C9400P17, 1C9400P18, and 1C9400P19, in unison, and lower upper
HPC stator case down to fit onto lower HPC stator case.
(6) Remove jacks, 1C9400P17, 1C9400P18, and 1C9400P19.
(7) Clean and store all tools from fixture set, 1C9400, in container, 1C9400P02.
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WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
C. Using clean cloth moistened with isopropyl alcohol, clean horizontal flange contact
faces of upper and lower HPC stator cases.
CAUTION
Do not over tighten bolts securing vane holding fixture, 2C6259, or
tool damage will result.
NOTE
The shims contain through-holes in line with the case flange
holes to permit bolting of the halves together and to later install
the hinges without having to remove the shims.
D. Install vane holding fixture, 2C6259, onto VSV stages 3-5. See figure 2. Secure using
washers and bolts. Tighten bolts only enough to secure vane holding fixture in place.
CAUTION
Ensure compressor vane levers are positioned fully open to
prevent damage to rotor spool.
E. Install brackets, bolts, and nuts at aft circumferential flange. Install hardware at
locations marked during disassembly. Do not tighten nuts at this time.
F. Apply thread lubricant to threads of forward circumferential flange attaching bolts.
G. Install brackets and bolts at forward circumferential flange. Install hardware at
locations marked during disassembly. Do not tighten bolts at this time.
H. Install horizontal flange retaining hardware as follows:
(1) Apply thread lubricant to threads and washer faces of horizontal flange attaching
bolts. See figure 6.
(2) Ensure flanges are in contact on both sides over their full length. If required,
install clamps or bolts at forward and aft ends and tighten slightly to pull flanges
together. Do not overtighten clamps or bolts so that alignment pins cannot
function. Do not remove these clamps or bolts until assembly bolts are installed
and tightened to final torque.
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NOTE
Bolt positions on the horizontal flanges are counted from the aft
flange forward.
(3) Install body-bound bolts or alignment pins from tool set, 2C14779, in horizontal
flange bolthole locations 2, 5, 9, 21, 25, 31, and 35, counting from aft end on both
sides. See figure 6.
(4) Ensure that body-bound bolts or alignment pins are fully seated. Restrain pins
using Allen wrench and tighten nuts on small diameter pins to 40 lb in. (4.5 N·m)
of torque. Use socket from tool set, 2C14779, to enable access in tight clearance
areas. Avoid side loads.
(5) Restrain pins using Allen wrench and tighten nuts on large diameter pins to
240 lb in. (27.1 N·m) of torque.
(6) Install bolts, spacers, and nuts in remaining horizontal flange boltholes per
figure 6.
(7) Tighten nuts, in sequence, starting from aft end and alternating from flange to
flange. For ease of assembly, it is permitted to advance up to four bolts farther
along one horizontal flange than the other. Tighten nuts to torque values listed in
figure 6.
(8) Remove alignment pins and replace with body-bound bolts, spacers, and nuts per
figure 6.
(9) Tighten nuts, in sequence, starting from aft end and alternating from flange to
flange. Tighten nuts to torque values listed in figure 6.
(10) Tighten horizontal flange bolts with spacers, starting from aft end and alternating
from flange to flange. Do not unseat nuts during retightening.
I. Tighten aft circumferential flange nuts to 380-420 lb in. (42.9-47.5 N·m) of torque.
Tightening sequence is as follows (figure 8):
(1) Tighten four bolts from horizontal flange.
(2) Tighten four bolts from top vertical centerline.
(3) Continue tightening aft circumferential flange bolts, alternating from side to side,
until all nuts are tightened.
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J. Tighten forward circumferential flange bolts to torque values listed in figure 9.
Safety-wire bolts in groups of two or three.
K. Remove jack assembly, 1C9376.
L. Connect VSV actuating mechanism as follows:
(1) Remove vane holding fixture, 2C6259, from VSV stages 3-5.
(2) Install connecting links as follows (figure 1):
(a) Loosen self-locking nuts that secure first five vane arms at each end of upper
and lower stage 5 actuator rings. Loosen self-locking nut until flush with end
of vane stem.
CAUTION
Connecting links shall be installed on correct stage and with
lever arm pins engaging sleeves, or VSV off-schedule opera-
tion and engine damage may result.
(b) Install sleeves into connecting link ID. Ensure connecting link is correct for
stage being installed.
(c) Position connecting link onto actuation rings, ensuring FWD marking faces
forward. Install IGV and stages 1-4 lineup pins, ensuring lever arm pins
engage sleeves.
(d) Install bolts and washers onto IGV and stages 1-4. Install bolts onto stage 5.
Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque and safety-wire.
(e) Ensure all lever arm pins are engaged in sleeves and are not engaged with
connecting link lightening holes.
CAUTION
Stage 5 vane stem self-locking nuts loosened in substep (a)
shall be retorqued, or damage to engine will occur.
(f) Tighten self-locking nuts loosened in substep (a) to 50-70 lb in. (5.6-7.9 N·m)
of torque.
(3) Install VSV hydraulic actuators, actuator brackets, and actuation levers per
WP 1410 00.
(4) Install upper fuel manifold sections per WP 1510 00.
(5) Install piping per SWP 1913 02.
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WP 2412 00
5WP 2412 00
WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR (HPC) STATOR
VANES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 80
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 80 ...... 3
Alphabetical Index
Subject Page
HPC IGV and Stage 1-5 Variable Stator Vanes Dimensional Inspection ................................... 20
HPC IGV and Stage 1-5 Variable Stator Vanes Visual Inspection.............................................. 16
HPC Stage 6-13 Stator Vanes Dimensional Inspection............................................................... 24
HPC Stage 6-13 Stator Vanes Visual Inspection......................................................................... 20
HPC Stator Case Inspection ........................................................................................................ 30
HPC Stator Case - Repair of VSV Bushing Mounting Hole Threads......................................... 30
HPC Stator Vanes Installation..................................................................................................... 51
HPC Stator Vanes Removal ........................................................................................................ 4
Parts Repair - Vanes - General .................................................................................................... 27
Parts Repair - Vanes - Leading and Trailing Edge Blending ...................................................... 28
Parts Repair - Vanes - Tip Blending............................................................................................ 30
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WP 2412 00
1. Introduction.
NOTE
The LM6000 HPC high-boss case stages 3-5 bushings are replaceable
externally without top case removal. Refer to WP 1412 00 for replace-
ment instructions.
This work package contains instructions for removing and installing the high pressure
compressor (HPC) stator case.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Maintenance Considerations Chapter 11
Variable Stator Vane (VSV) stages 3 to 5 Bushing Replace-
ment (High-Boss HPC Stator Case) WP 1412 00
High Pressure Compressor (HPC) Upper and Lower Stator WP 2411 00
Case Replacement
Variable Stator Vane Off-Schedule Inspection WP 4028 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Tool Set, Jackscrew 1C9150G02
Fixture Set, VSV Torque Measuring 1C9408G02
Wrench, VSV Locknut Torque Break 1C9428G01
Tool Set, Holding VSV 2C6018G01
Driver Set, Compressor Stator Vane 2C6019G03
Holder Set, VSV 2C6171G02
Removal Tool, Vane Spring Retainers 2C14684G02
Bushing Rework Tool - WP2412-03 Local Manufacture
Depth Gage - WP2412-02 Local Manufacture
Drilling Jig - WP2412-01 Local Manufacture
Drill Stop, Adjustable Local Purchase
(7/32 inch Diameter)
Pull Scale, Calibrated 0-50 lb Local Purchase
7/32 inch Diameter Drill (case rework) Local Purchase
HSS 0.250-28 UNJF-3B Tap Set Local Purchase
(Taper, Plug and Bottoming Taps)
7 mm or 9/32 inch Diameter Drill Local Purchase
(bushing rework)
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Nomenclature Part No.
8492A102 Drill Guide (Ref. McMaster) Local Purchase
8492A176 Drill Guide (Ref. McMaster) Local Purchase
Adjustable Drill Stop (7/32 Inch Local Purchase
Diameter)
3374A21 Transfer Punch (Ref. Local Purchase
McMaster)
4. Consumable Material.
Nomenclature Specification
Deleted
Isopropyl Alcohol Fed Spec TT-I-735
Marking Pen Sharpie T.E.C.
(Black or Blue)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Sharpening Stone Fed Spec SS-S-736
Silicone Rubber Adhesive GE Spec A15F6B6
(RTV 106)
Tapping Fluid Trim Tap NC
(Masters
Chemical Co.)
Thread Lubricant GE Spec A50TF201
5. Referenced Procedures.
Chapter 11 Hand Blending
Chapter 11 Marking of Parts
Chapter 11 Spot Fluorescent Penetrant Inspection
Chapter 11 Swab Etching Procedures
6. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed L47372P01 58
(Stage 5 Hi-Boss Case)
Packing, Preformed L47372P02 96
(Stages 3 and 4 Hi-Boss Case)
Spring Retainer, Stages 6 and 8 9382M94P02 127
Spring Retainer, Stages 9, 10, 12, and 13 9382M95P05 300
Change 3 3
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7. SPD Information.
Nomenclature Part No.
Bushing - Spare Part 2083M62P01
through P08
8. HPC Stator Vanes Removal.
A. Before disassembly, inspect inlet guide vane (IGV) and stages 0-5 stator vanes for
off-schedule condition per WP 4028 00.
B. Remove HPC stator cases per WP 2411 00.
C. Remove stages IGV-2 stator vanes as follows:
(1) Remove stages IGV-2 vane shrouds as follows (figure 1):
(a) Using marking pen, position mark shroud sections.
1
NOTE
• The forward and aft parts of each shroud half section are a
matched set. If either part requires replacement, the entire half
section shall be replaced.
• Shroud retaining bolts are body-bound. Do not allow bolts to turn
during removal.
(b) Remove nuts from shroud retaining bolts. Support vanes and tap bolts out
using a plastic mallet. Separate and remove forward and aft shroud segments.
(c) Remove flanged bushings from vane inner trunnions.
(2) Using marking pen, position mark vanes to stator case.
(3) Using holding tool from holding VSV tool set, 2C6018, support individual vanes.
Support entire stage of vanes using holder from VSV holder set, 2C6171.
See figure 2.
2
(4) Loosen locknut using torque break wrench, 1C9428, and channel-lock pliers. See
figures 3 and 4. Remove locknut (1, figure 4), alignment sleeve (2), and lever arm
4
3
(5) If a large number of vanes are being removed, remove all lever arms (3) and
remove actuation ring (11).
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Figure 1. Stages IGV-2 Vane Shrouds Removal
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Figure 2. Variable Stator Vane Holding Tools
CAUTION
Bushing may stick in stator case counterbore. Ensure all
pieces are removed before installing new parts.
(6) Remove spacer (5) and bushing (6) from outside of stator case (12).
(7) Remove vane (8) by pulling from inside of stator case (12).
(8) Remove washer (7) from inside of stator case (12).
(9) If HPC stator cases are to be replaced, remove stages IGV-2 borescope plugs from
stator case.
D. Remove stages 3-5 stator vanes as follows:
(1) Using marking pen, position mark vanes to stator case.
(2) Using holding tool from VSV tool set, 2C6018, support individual vanes. Support
entire stage of vanes using holding tool from VSV holder set, 2C6171.
See figure 2.
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Figure 3. Stages IGV-4 Locknut Removal
(3) Remove high-boss case vanes as follows (figure 5 or figure 5.A):
5
(a) Remove locknut (1) and lever arm (2).
(b) Remove jamnut (3), alignment sleeve (4), and spacer (5).
(c) Remove vane (9) by pulling from inside of high-boss case (12).
(d) If large number of vanes are being removed, remove all lever arms (2) and
remove actuation ring (11) and actuation ring sleeves (10).
(e) Before Service Bulletin LM6000-IND- 0213, remove bushing (6) as follows:
1 Remove bolts (7) that secure bushing (6) to high-boss case (12).
2 Use nylon drift to loose bushing (6), as required.
3 Remove bushing (6) and discard preformed packing (8).
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Figure 4. Stages IGV-2 Stator Vanes
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Figure 5. High-Boss Case Stages 3-5 Vane Removal Before Service Bulletin LM6000-IND-0213
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Figure 5.A. High-Boss Configuration After Service Bulletin LM6000-IND-0213
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(f) After Service Bulletin LM6000-IND-0213, remove housing (6), washer (8), and
bushing (13) as follows:
1 Remove bolts (7) that secure housing to high-boss case (12)
2 Remove washer (8), housing (6), and bushing (13).
(g) If upper and lower HPC stator cases are to be replaced, remove stages 3-5 borescope
plugs from stator case.
E. Remove stages 6-12 stator vanes as follows:
(1) Remove borescope plugs from HPC stator case on effected stages.
(2) Using marking pen, position mark vanes to HPC stator case.
(3) Remove vane retaining keys from horizontal flanges of upper HPC stator case (figure 6).
Lower HPC stator case has no retaining keys.
6
NOTE
Stages 7 and 11 do not have spring retainers.
(4) On stages 7 and 11, remove vanes by sliding circumferentially from retaining slots. Use
driver from compressor stator vane driver set, 2C6019, to drive against vane base, not
airfoil.
CAUTION
Do not slide vanes with spring retainers installed. Spring retainers
will scar case.
(5) On stages 6, 8, 9, 10, and 12, remove vanes to expose first spring retainer by sliding
circumferentially from retaining slots.
(6) Using stator vane spring retainer removal tool, 2C14684, remove spring retainers.
(figure 7). Discard spring retainers.
7
(7) Remove remaining vanes and retainers per steps (5) and (6).
F. Remove stage 13 stator vanes as follows (figure 8):
8
(1) Remove borescope plug from lower HPC stator case.
(2) Using marking pen, position mark liner segments to HPC stator case.
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Figure 6. Stages 6-12 Stator Vane Removal (Sheet 1 of 2)
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Figure 6. Stages 6-12 Stator Vane Removal (Sheet 2 of 2)
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Figure 7. Stages 6-12 Vane Removal Tools
(3) Remove bolts that secure liner segments to HPC stator case.
CAUTION
Use care so end-stop does not fall out of the liner segments
and leaf seals do not become disengaged.
(4) Remove liner segments by sliding circumferentially from retaining slots.
(5) Remove stationary seal segments.
(6) Attempt to remove end-stop from liner. Early configuration end-stops cannot be
removed. See figure 8.
(7) If end-stop is not removable, remove vanes from end of liner opposite end-stop.
(8) If end-stop is removable, remove vanes as follows:
(a) Remove end-stop and leaf seals from liner.
(b) Remove vane to expose first spring retainer by sliding circumferentially from
liner retaining slots, sliding it over liner end-stop pin.
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Figure 8. Stage 13 Vane Removal
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(c) Using vane spring retainer removal tool, 2C14684, remove exposed spring retainer
(figure 7). Discard spring retainer. See figure 8.
(d) Slide second vane toward liner end-stop pin to expose next spring retainer.
(e) Repeat steps (c) and (d) until all spring retainers are removed from liner.
(f) Remove vanes from end of liner opposite end-stop pin.
(g) Install end-stop and leaf seals to liner. Retain end-stop in place with two rubber bands,
one around each end of end-stop.
G. If HPC stator cases are to be replaced, remove variable stator vane (VSV) lever bracket from
stator case.
9. HPC IGV and Stage 1-5 Variable Stator Vanes Visual Inspection.
A.Visually inspect IGV and stage 1-5 vanes per tables 1 and 2, and figure 9.
Table 1. HPC IGV and Stage 1-5 Vanes Visual Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
NOTE
Airfoil defects within defined limits resulting in protrusion on the
opposing surface are acceptable. Defects superimposed at same
airfoil location but on opposing sides are not acceptable if sum of
two defects exceeds defined limits.
1. All Areas for:
a. Cracks Not serviceable Not repairable Replace vane
2. Area A for (figure 9):
a. Nicks, pits, 0.003 inch (0.08 mm) 0.010 inch (0.25 mm) Blend per paragraph 13
and scratches deep deep
b. Dents 0.010 inch (0.25 mm) Not repairable Replace vane
deep. None allowed in
fillets
3. Area B (Leading and Trailing Edges) for (figure 9):
a. Nicks, pits, 0.005 inch (0.13 mm) Any amount if repair Blend per paragraphs
and scratches deep does not exceed min 13 and 14
Chord V (table 2)
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Table 1. HPC IGV and Stage 1-5 Vanes Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Dents 0.020 inch (0.51 mm) Any amount if repair Blend per paragraphs
deep does not exceed min 13 and 14
Chord V (table 2)
c. Erosion Min root Chord V and Any amount if repair Blend per paragraphs
min thicknesses, mea- does not exceed min 13 and 14
sured 0.03 inch Chord V (table 2)
(0.8 mm) from lead-
ing/trailing edge are
0.012 inch (0.30 mm)
in area from root to
midspan and
0.010 inch (0.25 mm)
in area from midspan
to tip
4. Area C for (figure 9):
a. Nicks, pits, 0.003 inch (0.08 mm) 0.010 inch (0.25 mm) Blend per paragraph 13
and scratches deep deep
b. Dents 0.010 inch (0.25 mm) Not repairable Replace vane*
deep. None permitted
in fillets
5. Area G (Stage 3-5 Squealer Tips) for (figure 9):
a. Cracks, nicks, Not serviceable 0.030 inch (0.76 mm) Blend per paragraphs
and dents deep 13 and 15
b. Burrs and high Not serviceable Any amount Remove high metal
metal
c. Top tip corner Not serviceable Max blend radius Blend per paragraphs
damage (figure 9) must remove 13 and 15
all defective material.
Rework may extend
into areas B and C
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Table 1. HPC IGV and Stage 1-5 Vanes Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
d. Airfoil 0.020 inch (0.51 mm) Not repairable Replace vane*
bending for each 1.0 inch
(25 mm) of airfoil
length
6. Area E (IGV, Stage 1-2 Trunnions, Platforms, and Tangs) for (figure 9):
a. Nicks and 0.005 inch (0.13 mm) 0.015 inch (0.38 mm) Blend high metal per
scratches deep if 80 percent of deep if 30 percent of paragraph 13
area is clear of defects. area is clear of defects
None allowed in fillets
and no raised metal
b. Scoring or wear 0.010 inch (0.25 mm) 0.020 inch (0.51 mm) Replace vane*
on outer deep, 0.100 inch deep
trunnion (2.54 mm) wide
diameter
c. Scoring or wear 0.020 inch (0.51 mm) Not repairable Replace vane*
on inner deep for 50 percent of
trunnion circumference
diameter
d. Wear on outer 0.010 inch (0.25 mm) Not repairable Replace vane*
platform deep
surface
e. Wear on inner 0.010 inch (0.25 mm) Not repairable Replace vane*
platform face deep
f. Runout of inner 0.020 inch (0.51 mm) Not repairable Replace vane*
trunnion FIR
diameter with
respect to outer
trunnion
diameter (IGV-
2 only)
g. Scoring or wear 0.010 inch (0.25 mm) Not repairable Replace vane*
on tang deep
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Table 1. HPC IGV and Stage 1-5 Vanes Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
h. Wear on inner 0.030 inch (0.76 mm) Not repairable Replace vane*
platform outer deep
edge
7. Area F (Threaded Stem) for (figure 9):
a. Thread damage Not serviceable Entrance thread may Remove entrance
be removed if remain- thread or replace vane
ing threads are not
damaged
b. High metal Not serviceable Any amount Remove high metal per
paragraph 13
* NOTE: May be repairable; consult GE for disposition of replaced parts.
Table 2. HPC IGV and Stage 1-5 Vanes Minimum Chord Values
Minimum Chord V
Dim D
IGV Stage 1 Stage 2
inches mm inches mm inches mm inches mm
Root Root 2.26 57.4 2.02 51.3 1.74 44.2
0.50 12.7 2.24 56.9 2.00 50.8 1.73 43.9
1.00 25.4 2.19 55.6 1.96 49.8 1.69 42.9
1.50 38.1 2.14 54.4 1.92 48.8 1.66 42.2
2.00 50.8 2.08 52.8 1.88 47.8 1.63 41.4
2.50 63.5 2.03 51.6 1.83 46.5 1.60 40.6
3.00 76.2 1.98 50.3 1.80 45.7 1.57 39.9
3.50 88.9 1.92 48.8 1.75 44.5 1.53 38.9
4.00 101.6 1.87 47.5 1.70 43.2 1.50 38.1
4.50 114.3 1.81 46.0 1.64 41.7 1.46 37.1
5.00 127.0 1.76 44.7 1.59 40.4 1.43 36.3
5.50 139.7 1.71 43.4 1.52 38.6 1.40 35.6
6.00 152.4 1.65 41.9 1.46 37.1
6.50 165.1 1.60 40.6 1.40 35.6
7.00 177.8 1.55 39.4
7.50 190.5 1.49 37.8
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Table 2. HPC IGV and Stage 1-5 Vanes Minimum Chord Values (Continued)
Minimum Chord V
Dim D
IGV Stage 1 Stage 2
inches mm inches mm inches mm inches mm
Minimum Chord V
Dim D
Stage 3 Stage 4 Stage 5
inches mm inches mm inches mm inches mm
Root Root 1.64 41.7 1.50 38.1 1.26 32.0
0.50 12.7 1.60 40.6 1.48 37.6 1.25 31.8
1.00 25.4 1.54 39.1 1.42 36.1 1.21 30.7
1.50 38.1 1.48 37.6 1.37 34.8 1.17 29.7
2.00 50.8 1.44 36.6 1.34 34.0 1.15 29.2
2.50 63.5 1.42 36.1 1.31 33.3 1.12 28.4
3.00 76.2 1.39 35.3 1.29 32.8 1.09 27.7
3.50 88.9 1.36 34.5 1.27 32.3 1.06 26.9
4.00 101.6 1.32 33.5 1.24 31.5
4.50 114.3 1.29 32.8
9
10. HPC IGV and Stage 1-5 Variable Stator Vanes Dimensional Inspection.
NOTE
Dimensional inspections should follow all required repairs.
A. Dimensionally inspect IGV and stage 1-5 vane chord (Dimension V) as follows:
(1) Measure vane Chord V at Dimensions D listed in table 2. See figure 9.
(2) Check measured Chord V with table 2 limits. Replace vanes as required.
B. Dimensionally inspect vane length (Dimension L) of stage 3-5 vanes per table 3, and
figure 10.
10
11. HPC Stage 6-13 Stator Vanes Visual Inspection.
A.Visually inspect stage 6-13 vanes per table 4, and figure 11.
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Figure 9. IGV and Stages 1 Through 5 Vanes Inspection Areas
1
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Table 3. Stage 3-5 Vane Length Dimension L Inspection
Stage Minimum Vane Length Corrective Action
3 5.027 in. (127.69 mm) Replace vane
4 4.255 in. (108.08 mm) Replace vane
5 3.619 in. (91.92 mm) Replace vane
NOTE
The lengths tabulated represent the shortest vanes which should
occur as a result of assembly processing (minimum radius case and
maximum grind).
Figure 10. Stages 3–5 Vanes Length Dimension L Inspection
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Table 4. HPC Stages 6-13 Vanes Visual Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
NOTE
Airfoil defects within defined limits resulting in protrusion on the
opposing surface are acceptable. Defects superimposed at same
airfoil location but on opposing sides are not acceptable if sum of
two defects exceeds defined limits.
1. All Areas for (figure 11):
a. Cracks Not serviceable Not repairable Replace vane*
2. Area A for (figure 11):
a. Nicks, pits, 0.005 inch (0.13 mm) 0.010 inch (0.25 mm) Blend per paragraph 11
and scratches deep deep
b. Dents 0.010 inch (0.25 mm) Not repairable Replace vane*
deep. None allowed in
fillets
3. Area B (Leading and Trailing Edges) for (figure 11):
a. Nicks, pits, 0.005 inch (0.13 mm) Any amount if repair Blend per paragraphs 11
and scratches deep does not exceed min and 12
Chord V (table 5)
b. Dents 0.020 inch (0.51 mm) Any amount if repair Blend per paragraphs 11
deep does not exceed min and 12
Chord V (table 5)
c. Erosion Min root Chord V and Any amount if repair Blend per paragraphs 11
min thicknesses, mea- does not exceed min and 12
sured 0.030 inch Chord V (table 5)
(0.76 mm) from lead-
ing/trailing edge are
0.012 inch (0.030 mm)
in area from root to
midspan and
0.010 inch (0.25 mm)
in area from midspan
to tip
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Table 4. HPC Stages 6-13 Vanes Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
4. Area G (Squealer Tips) for (figure 11):
a. Cracks, nicks, Not serviceable 0.030 inch (0.76 mm) Blend per paragraphs 13
and dents deep and 15
b. Burrs and high Not serviceable Any amount Remove high metal
metal
c. Tip corner Not serviceable Max blend radius (see Blend per paragraphs 13
damage figure 11) must remove and 15
all defective material.
Rework may extend
into areas B and G
5. Areas E, H, and J (Vane Base) for (figure 11):
a. Dovetail 10 percent of parent - Replace vane
coating missing metal exposed
b. Dovetail Not to parent metal - Replace vane
coating wear
c. Dovetail parent Not serviceable - Replace vane
metal wear
d. Nicks and 0.020 inch (0.51 mm) 0.030 inch (0.76 mm) Blend per paragraph 13
scratches other deep. None allowed in deep
than dovetail fillets. Remove high
surfaces metal
e. Wear from 0.005 inch (0.13 mm) 0.050 inch (1.27 mm) Remove high metal per
retaining key deep deep paragraph 13
f. Platform end Any amount, not into Not repairable Replace vane
fretting airfoil root radius fillet
12. HPC Stage 6-13 Stator Vanes Dimensional Inspection.
NOTE
Dimensional inspections should follow all required repairs.
A. Dimensionally inspect stage 6-13 vane chord (Dimension V) as follows:
(1) Measure vane Chord V at Dimension D listed in table 5. See figure 11.
(2) Check measured Chord V with table 5 limits. Replace vanes as required.
B. Inspect stage 6-13 vane length (Dimension L) per table 6 and figure 12.
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Figure 11. Stages 6 Through 13 Vanes Inspection Areas
1
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Table 5. HPC IGV and Stage 1-5 Vanes Minimum Chord Values
Minimum Chord V
Dim D
Stage 6 Stage 7 Stage 8
inches mm inches mm inches mm inches mm
Root Root 1.34 34.0 1.23 31.2 1.26 32.0
0.50 12.7 1.32 33.5 1.22 31.0 1.24 31.5
1.00 25.4 1.28 32.5 1.16 29.5 1.22 31.0
1.50 38.1 1.24 31.5 1.11 28.2 1.20 30.5
2.00 50.8 1.20 30.5 1.06 26.9 1.17 29.7
2.50 63.5 1.16 29.5 1.01 25.7 1.14 29.0
3.00 76.2 1.11 28.2
Minimum Chord V
Dim D
Stage 9 Stage 10 Stage 11
inches mm inches mm inches mm inches mm
Root Root 1.21 30.7 1.11 28.2 1.12 28.4
0.50 12.7 1.20 30.5 1.10 27.9 1.12 28.4
1.00 25.4 1.16 29.5 1.08 27.4 1.08 27.4
1.50 38.1 1.13 28.7 1.04 26.4 1.02 25.9
2.00 50.8 1.10 27.9 0.98 24.9
2.50 63.5
3.00 76.2
Minimum Chord V
Dim D
Stage 12 Stage 13
inches mm inches mm inches mm
Root Root 1.14 29.0 0.86 21.8
0.50 12.7 1.13 28.7 0.86 21.8
1.00 25.4 1.07 27.2 0.86 21.8
1.50 38.1 0.99 25.1 0.86 21.8
2.00 50.8
2.50 63.5
3.00 76.2
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Table 6. Stage 3-5 Vane Length Dimension L Inspection
Stage Minimum Vane Length Corrective Action
6 3.269 in. (83.03 mm) Replace vane
7 2.855 in. (72.52 mm) Replace vane
8 2.573 in. (65.35 mm) Replace vane
9 2.231 in. (56.67 mm) Replace vane
10 2.030 in. (51.56 mm) Replace vane
11 1.818 in. (46.18 mm) Replace vane
12 1.646 in. (41.81 mm) Replace vane
13 1.520 in. (38.61 mm) Replace vane
NOTE
The lengths tabulated represent the shortest vanes which should
occur as a result of assembly processing (minimum radius case and
maximum grind).
13. Parts Repair - Vanes - General.
A. Use smooth file when repair blending compressor vanes not over 8 inches (200 mm) long, or
emery cloth to remove nicks and dents when removal of considerable material is necessary. File
or blend in longitudinal direction (parallel with airfoil length). Power tools may be used for ini-
tial heavy removal of material such as excessive tip curl. Final blend and polish
0.020–0.030 inch (0.51–0.76 mm) must be accomplished by hand.
CAUTION
All blend repair and polishing shall be done in direction parallel
with the vane leading or trailing edges. Do not use power tools for
final polish or finish blending.
B. Use medium stone on any areas which have been blended with file or emery cloth, and
on areas containing small nicks and dents.
C. Use fine emery cloth and/or fine abrasive stone to polish blended area until finish looks and
feels like original.
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Figure 12. Stages 6–13 Vanes Length Dimension L
D. Blend leading edges to as near original configuration as possible. Blend trailing edges
to remove all sharp edges (figure 13).
13
14. Parts Repair - Vanes - Leading and Trailing Edge Blending.
A. Blend leading and trailing edges to within maximum repairable limits of figure 9.
Contour blend edges per figure 13.
B. When blending out cracks, blend away enough material to remove defect and continue
to blend an additional 0.015 inch (0.38 mm).
CAUTION
When power blending out cracks, blend away enough material to
remove defect and continue to blend an additional 0.015 inch
(0.38 mm).
C. Power tools may be used to shorten time required to remove metal but hand bench last
0.005 inch (0.13 mm).
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Figure 13. Compressor Vane Blending
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D. After blending, spot-fluorescent-penetrant-inspect per Volume 1, Chapter 11. No cracks
allowed.
15. Parts Repair - Vanes - Tip Blending.
A. Blend to within limits of figure 9.
B. Blends may be 0.100 inch (2.54 mm) maximum depth on 20 percent of vanes per stage.
16. HPC Stator Case Inspection.
A. Inspect HPC stator case per table 7.
Table 7. HPC Stator Case Inspection
Maximum Maximum
Serviceable Repairable
Inspect Limit Limit Repair Method
1. High Boss Field Repair Stages 3-5 VSV Bushing Mounting Holes for:
a. Damage to Loss of first Any amount Repair per
threads full thread paragraph 17
17. HPC Stator Case - Repair of VSV Bushing Mounting Hole Threads.
A. This procedure provides instructions to field repair stages 3-5 VSV bushing mounting hole
threads in the HPC stator case by drilling two new holes 90º from the original holes and
tapping new threads. Refer to figure 14. Dimensional information for this repair is given in
figure 15.
14
15
16
B. Locally manufacture drilling jig for stages that have damaged VSV bushing mounting
holes. Refer to figure 16.
C. Locally manufacture drilling jig depth gage. Refer to figure 17.
D. Locally manufacture bushing rework tool. Refer to figure 18.
E. Install locally manufactured drilling jig onto damaged VSV bushing mounting holes as
follows. Refer to figure 19
(1) If case is off engine, place drilling jig in VSV hole. Tighten bolt to secure tool to
VSV hole. Tighten bolt to 50-70 lb in. (5.6-7.9 N·m) of torque.
(2) If case is assembled, install drilling jig using vane stem and a nut.
Refer to figure 19, sheet 2.
(3) Ensure drilling jig is correctly attached and seated against case wall and guiding
holes are in correct position.
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Figure 14. Stages 3-5 VSV Bushing Mounting Holes
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Figure 15. Case Rework Dimensional Information
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Figure 16. Locally Manufactured Drilling Jig (Sheet 1 of 6)
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Figure 16. Locally Manufactured Drilling Jig (Sheet 2 of 6)
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Figure 16. Locally Manufactured Drilling Jig (Sheet 3 of 6)
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Figure 16. Locally Manufactured Drilling Jig (Sheet 4 of 6)
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Figure 16. Locally Manufactured Drilling Jig (Sheet 5 of 6)
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Figure 16. Locally Manufactured Drilling Jig (Sheet 6 of 6)
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(4) Using drilling jig base and locally manufactured depth gage, adjust drill depth to
ensure depth of drilled hole in HPC case does not exceed limit of 0.370 inch
(9.39 mm). Refer to figure 17, sheet 3.
CAUTION
Assure drill stop is secure and depth is set on the drill or damage to
case may occur.
F. Drill two new holes located on the opposite position to old damaged holes. Refer to
figure 15. Ensure you use the transfer punch to facilitate drilling.
G. Deburr machined holes. Refer to Chapter 11, Hand Blending.
H. Tap threads inside new drilled holes. Refer to requirements of figure 15. Use thread
tapping fluid.
I. Deburr machined threads. Refer to Chapter 11, Hand Blending.
J. Do a swab etch of all repaired areas. Refer to Chapter 11, Swab Etching Procedures.
K. Do a spot fluorescent penetrant inspection of compressor stator case. Refer to
Chapter 11, Spot Fluorescent Penetrant Inspection.
(1) All indications less than 0.03 in. (0.76 mm) are permitted.
(2) Indications less than 0.06 in. (1.5 mm), not interpreted as linear indications, are
permitted.
17
18
19
(3) The above defects are permitted if they are not closer than 0.5 in. (12.7 mm).
L. Select correct bushing. Rework bushing by drilling two holes 90° from existing two
mounting holes. Use bushing rework tool. Refer to figure 18.
M. Deburr machined holes. Refer to Chapter 11, Hand Blending.
N. Reidentify reworked bushing to 2083M62. Refer to Chapter 11, Marking of Parts.
O. Install bushing on repaired VSV holes. Use standard compressor case bolts to attach
replacement bushings to VSV mounting holes. Refer to figure 20.
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Figure 17. Drilling Jig Depth Gage (Sheet 1 of 3)
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Figure 17. Drilling Jig Depth Gage (Sheet 2 of 3)
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Figure 17. Drilling Jig Depth Gage (Sheet 3 of 3)
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Figure 18. Bushing Rework Tool (Sheet 1 of 6)
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Figure 18. Bushing Rework Tool (Sheet 2 of 6)
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Figure 18. Bushing Rework Tool (Sheet 3 of 6)
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Figure 18. Bushing Rework Tool (Sheet 4 of 6)
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Figure 18. Bushing Rework Tool (Sheet 5 of 6)
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Figure 18. Bushing Rework Tool (Sheet 6 of 6)
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Figure 19. Drilling Jig Installation (Sheet 1 of 2)
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Figure 19. Drilling Jig Installation (Sheet 2 of 2)
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18. HPC Stator Vanes Installation.
A. Install stages IGV-2 stator vanes as follows:
(1) Install bushing (6, figure 4) into vane (8) counterbore on stator case (12) outer
diameter. Press bushing evenly to avoid snagging or cracking. Locally fabricate
installation tool per figure 21 and use to install bushings, if required.
CAUTION
Deleted.
(2) Install washer (7, figure 4) onto vane (8). Install vane into stator case (12). Washer
shall protrude into case bore when vane is installed.
(3) Install spacer (5) and lever arm (3) onto vane (8). Ensure spacer and lever arm
slide over vane tangs.
(4) Install alignment sleeve (2) and locknut (1) onto vane (8). Ensure alignment
sleeve seats between vane tangs.
CAUTION
Do not use lever arm to hold vane when torquing locknut, or lever
will be damaged.
1
20
(5) Using vane holding tool from VSV tool set, 2C6018, and torque wrench, tighten
locknut (1) to 65-75 lb in. (7.3-8.5 N·m). A minimum of two threads shall show
beyond nut if parts are seated properly.
(6) Measure stages IGV-2 vane rotational torque as follows:
(a) Manually rotate vane (8) several times to ensure assembly is seated.
CAUTION
Failure to meet proper vane rotational torque may cause binding
and result in bent lever arm.
(b) Check that vane (8) rotational torque is between 2-10 lb in. (0.2-1.1 N·m).
Replace spacer (5), as required, to obtain proper rotational torque.
See figure 22.
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Figure 20. SPAD Bushing Installation
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Figure 21. VSV Bushing Installation Tool
NOTE
A thinner spacer will reduce rotational torque. A thicker spacer
will increase rotational torque.
(c) Small changes to vane (8, figure 4) rotational torque may be accomplished by
lapping spacer face, using circular motion to remove material. Final surface
finish shall match original finish.
(d) Record final rotational torque of each vane (8). Torque value will be required
for checking total actuation load for half-ring segments.
1
(7) Ensure actuation travel limits of replacement vanes as follows:
(a) Check each replacement vane for freedom of travel through limits shown in
figure 23. If vane binds, check for interference adjacent to casing bore.
23
(b) Vane areas adjacent to casing bore may be blended to obtain clearance at
travel limits. See figure 24. Remove only enough material to eliminate
interference. Do not use power tools. Gap in reworked area shall not exceed
0.005 inch (0.13 mm). Original finish required. No undercutting allowed.
24
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Figure 22. VSV Spacer Thickness
(8) Ensure stages IGV-2 vanes are correctly seated using 0.004 inch (0.10 mm) feeler
stock between bushing and spacer. See figure 25. Parts are not seated correctly if
feeler stock can be inserted between bushing and spacer.
25
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Figure 23. Variable Vane Travel Limits
B. Install stages IGV-2 vane shrouds as follows:
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
(1) Using isopropyl alcohol, clean old silicone rubber adhesive from shroud retaining
bolts and nuts.
(2) Install bushings onto vane inner trunnions. See figure 26.
26
(3) Position forward and aft shroud segments onto bushings.
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Figure 24. Variable Vane Rework Areas
NOTE
Shroud retaining bolts are body-bound. Do not allow bolts to
turn during installation.
(4) Install shroud retaining bolts. On stage IGV, boltheads face aft. On stages 1 and 2,
boltheads face forward.
(5) Tighten nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
(6) Ensure actuation travel limits of replacement vanes as follows:
(a) Check each replacement vane for freedom of travel through limits shown in
figure 23. If vane binds, check for interference adjacent to shroud.
(b) Vane areas adjacent to shroud may be blended to obtain clearance at travel
limits. See figure 24. Remove only enough material to eliminate interference.
Do not use power tools. Gap in reworked area shall not exceed 0.005 inch
(0.13 mm). Original finish required. No undercutting allowed.
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Figure 25. Variable Stator Vane Seating Check
(7) Check that torque required to rotate vanes assembled into shrouds does not
exceed 15 lb in. (1.7 N·m).
WARNING
Vapor from uncured sealant is flammable and toxic to skin, eyes,
and respiratory tract. Avoid contact with skin and eyes. Use in a
well-ventilated area.
(8) Remove nuts one at a time, and fill nut threads with silicone rubber adhesive.
Install nuts before adhesive dries. Tighten nuts to 60-70 lb in. (6.8-7.9 N·m) of
torque.
(9) Use 0.001-inch (0.03 mm) feeler stock to check that shrouds are mated.
(10) Apply silicone rubber adhesive over nuts and exposed bolt threads, to a minimum
thickness of 0.032 inch (0.81 mm).
(11) Allow silicone rubber adhesive to cure for a minimum of 8 hours before engine
operation.
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Figure 26. Stages IGV-2 Vane Shrouds Installation
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C. Select and grind replacement stages 3-5 stator vanes as follows:
(1) Select replacement vane of equal length to, or slightly longer than, vane being
replaced. If replaced vane length cannot be determined, use length of shorter of
two adjacent vanes.
NOTE
Power blending shall be accomplished so no excessive heat and thermal
stresses are generated. Failure to comply may result in part damage.
(2) Hand-grind replacement vane to length of original vane +0.000 to -0.005 inch
(+0.00 to -0.13 mm). Maintain proper length and angle across vane tip. Stages
3-5 vanes have double angles on tip. Power tools may be used to shorten grinding
time but last 0.005 inch (0.13 mm) must be hand ground.
D. Install stages 3-5 stator vanes as follows:
(1) Install high-boss case stages 3-5 stator vanes (figure 27 or figure 27.A) as
follows:
27
(a) Visually check for evidence of locking feature on bolts (7, figure 27 or
figure 27.A). Lightly coat threads and seating surfaces of bolts with thread
lubricant.
1 Install self-locking bolts by hand into case. If bolts can be run into case
without stopping, self-locking feature is not adequate. Replace bolt with
new bolt.
2 If bolthole condition does not allow any self-locking fastener to engage
locking feature, remove adjacent self-locking bolt and install two
non-self-locking bolts so they may be safety-wired or safety-cabled
together.
(b) Before Service Bulletin LM6000-IND-0213, install bushing (6) into
high-boss case (12) outer bore. Secure with two bolts (7). Install bolts by
hand into case. Maximum installation torque of bolts is not to exceed 40 lb
in. (4.5 N·m). Tighten bolts to 85-105 lb in. (9.6-11.9 N·m) of torque. Install
non-self-locking bolts at borescope locations. Safety-wire or safety-cable
bolts to adjacent borescope plug.
(c) After Service Bulletin LM6000-IND-0213, pre-assemble multiple-piece
bushing assemblies as follows:
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Figure 27. High-Boss Case Stages 3-5 Vane Installation Before Service Bulletin LM6000-IND-0213
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Figure 27.A. High-Boss Stage 3 to 5 Configuration After Service Bulletin LM6000-IND-0213
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CAUTION
Part Numbers are not marked on new bushings and are diffi-
cult to differentiate by size and shape. Stage 5 bushings have a
paint marking on bushing barrel and stage 3 and 4 bushings
have no paint markings. Failure to assemble correctly may
cause VSV off-schedule operation.
Part Numbers are not marked on new washers and are diffi-
cult to differentiate by size and shape. Stage 5 washers have a
paint marking on washer face and stages 3 and 4 washers
have no paint markings. Failure to assemble correctly may
cause VSV off-schedule operation.
1 Pre-assemble multiple-piece bushing assemblies for stages 3, and 4 as
follows:
a Insert barrel end of unpainted stages 3, and 4 flanged bushing (13),
inside barrel end of stages 3 and 4 compressor stator vane actuation
housing (6).
b Insert unpainted stages 3 and 4 flat washer (8), in recessed area on
housings assembled in previous step.
2 Pre-assemble multiple-piece bushing assemblies for stage 5 as follows:
a Insert barrel end of painted stage 5 flanged bushing (13), inside barrel
end of stage 5 compressor stator vane actuation housing (6).
b Insert painted stage 5 flat washer (8), in recessed area on housings
assembled in previous step.
(d) After Service Bulletin LM6000-IND-0213, install multiple-piece bushing
assemblies into HPCS cases as follows:
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CAUTION
Multiple-piece bushing assemblies with cutouts are installed at
borescope locations. Improper installation will prevent borescope
use.
NOTE
Once assembled, the new multiple-piece bushing assemblies are
installed in the same manner as the one-piece bushing.
1 Install multiple-piece bushing assemblies, pre-assembled in step (c)
HPCS stages 3, and 4 high-boss case outer bores.
2 Install multiple-piece bushing assemblies with cutouts, pre-assembled in
step (c) into HPCS stages 3, and 4 high-boss case outer bores adjacent to
borescope ports.
3 Verify that borescope ports in stages 3, and 4 are not blocked. If blocked,
repeat steps 1, and 2. If not blocked, perform remaining installation steps.
4 Install multiple-piece bushing assemblies, pre-assembled in step (c) into
HPCS stage 5 high-boss case outer bores.
CAUTION
Ensure all stages 3-5 stator vanes have the letter V marked at
top of vane stem. Apex of V shall point forward. Failure to
comply may result in part damage.
(e) Install vane (9) into high-boss case (12). Ensure vane has letter V
marked on top of vane stem and that apex of V is pointing forward.
(f) Install spacer (5) and alignment sleeve (4) onto vane (9). Flat on alignment
sleeve faces forward.
(g) Install jamnut (3) onto vane (9). Using holding tool from holding VSV tool
set, 2C6018, and torque wrench, tighten jamnut to 50-70 lb in. (5.6-7.9 N·m)
of torque. Replace jamnut if run-on torque is more than 20 lb in. (2.3 N·m).
(h) Install lever arm (2) and locknut (1) onto vane (9) by hand. If nut can be run
onto vane without stopping, self-locking feature is not adequate. Replace nut
with new nut.
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CAUTION
Do not use lever arm to hold vane when torquing locknut, or lever
will be damaged.
(i) Using holding tool from holding VSV tool set, 2C6018, and torque wrench,
tighten locknut to 50-70 lb in. (5.6-7.9 N·m).
(2) Measure individual vane (9) rotational torque as follows:
(a) Manually rotate vane (9) several times to ensure assembly is seated.
CAUTION
Failure to meet proper vane rotational torque may cause binding
and result in bent lever arm.
NOTE
A 0.0 lb in. (0.0 N·m) torque limit implies that vane can rotate with a
minimum force applied. However, it is important to ensure that the
vane assembly is not loose after assembly as a result of a spacer that
is too thin. Vane assembly should be tight and should not rattle or
demonstrate any looseness.
(b) Ensure vane (9) rotational torque on high-boss case (12) is within 0-10 lb in.
(0.0-1.1 N·m).
(c) On high-boss case (12) installation, obtain vane (9) rotational torque as
follows:
1 If rotational torque is below limits, replace spacer (5).
2 If rotational torque is above limits, spacer (5) thickness may be reduced
by lapping spacer face, using figure eight motion to remove material.
Final surface finish shall match original.
(d) Record final rotational torque of each vane (9). Torque value will be required
for checking total actuation load for half-ring segments.
(3) Ensure actuation travel limits of replacement vanes (9) as follows:
(a) Check each replacement vane for freedom of travel through limits shown in
figure 23. If vane binds, check for interference adjacent to casing bore.
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(b) Vane areas adjacent to casing bore may be blended to obtain clearance at
travel limits. See figure 24. Remove only enough material to eliminate
interference. Do not use power tools. Gap in reworked area shall not exceed
0.005 inch (0.13 mm). Original finish is required. No undercutting is
allowed.
E. Connect lever arms (2, figure 27) to actuation rings (11) as follows:
(1) Loosen locknuts (1) enough to allow lever arm (2) pins to be inserted into
actuation ring sleeves (10).
(2) Insert lever arm (2) pins into actuation ring sleeves (10).
CAUTION
Do not use lever arm to hold vane when torquing locknut, or lever
will be damaged.
(3) Hold stages IGV-2 vane with holding tool from holding VSV tool set, 2C6018, or
VSV holder set, 2C6171, and tighten locknut (1) to 65-75 lb in. (7.3-8.5 N·m) of
torque. Use torque wrench, 2C6965P01.
(4) Hold stages 3-5 vane with holding tool from holding VSV tool set, 2C6018, or
VSV holder set, 2C6171, and tighten locknut (1) on high-boss case (12) to
50-70 lb in. (5.6-7.9 N·m) of torque.
F. Check actuation ring segment installation as follows (figure 28):
(1) Inspect stages IGV-4 actuation ring for presence of washers under spacer
locknuts. Install washer, if missing.
(2) Position vanes so lever arms point aft. Measure dim M at each spacer for all
stages.
(3) Adjust spacers, as required, to dim M limits. Tighten locknut to 70-90 lb in.
(7.9-10.2 N·m) of torque.
28
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Figure 28. Actuation Ring Spacer Clearance
G. Perform actuation ring pull check as follows:
NOTE
If HPC stator vanes being installed are for low-boss configuration,
use torque measuring fixture set, 1C9408G01; If high-boss configu-
ration, use torque measuring set, 1C9408G02.
(1) Using torque measuring fixture set, 1C9408, perform pull check on stages IGV-5
as follows:
NOTE
To perform pull check using a pull scale rather than fixture set,
1C9408, proceed to step (2).
(a) Remove parts from vane near center of actuation ring as shown in figure 29.
29
(b) Remove sleeve from actuation ring.
(c) Install dummy lever arm, locator plug, and drive adapter from torque
measuring fixture set, 1C9408.
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Figure 29. VSV Actuation Ring Pull Check
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(d) On stages IGV-2, tighten locator plug to 65-75 lb in. (7.3-8.5 N·m) of torque.
On stages 3-5 high-boss case, tighten locator plug to 50-70 lb in.
(5.6-7.9 N·m) of torque.
(e) Measure torque required to move actuation ring + 5 degrees from axial
position as shown in figure 30. On stages IGV-4, torque required shall not
exceed 140 lb in. (15.8 N·m). On stage 5, torque required shall not exceed
204 lb in. (23.0 N·m).
(2) Perform pull check using a pull scale as follows:
(a) Install slave bolt into actuation ring connecting link bolthole.
(b) Attach pull scale to slave bolt.
30
Figure 30. VSV Actuation Ring Travel
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(c) Measure force required to move actuation ring +5 degrees from axial position
as shown in figure 30. Multiply reading by the following scale factors to
obtain torque:
Stage Scale Factor
IGV 2.80 inches (71.1 mm)
1 2.72 inches (69.1 mm)
2 2.53 inches (64.3 mm)
3 2.18 inches (55.4 mm)
4 1.92 inches (48.8 mm)
5 1.20 inches (30.5 mm) (Before Service Bulletin LM6000-IND-0203)
1.46 inches (37.1 mm) (After Service Bulletin LM6000-IND-0203)
(d) On stages IGV-4, torque required shall not exceed 140 lb in. (15.8 N·m). On
stage 5, torque required shall not exceed 204 lb in. (23.0 N·m).
(3) Actuate each stage by hand, through complete open and closed mechanical travel.
Each stage shall move freely with no catching or binding.
(4) If pull check requirements are not met, perform the following:
(a) Check actuation ring spacer clearance per step F. Adjust as required.
(b) On stages IGV-2, check for vane binding at shrouds and HPC stator casing
bore. Correct, as required, per step A. or step B.
(c) On stages 3-5, check for vane binding at HPC stator casing bore. Correct, as
required, per step D.
(d) Check recorded rotation torques for individual vanes (reference step D.(3)).
Replace or rework spacers on vanes with high torques, as required, per
steps A. or D.
H. Select and grind replacement stages 6-13 stator vanes as follows:
(1) Select replacement vane of equal length to, or slightly longer than, vane being
replaced. If replaced vane length cannot be determined, use length of shorter of
two adjacent vanes.
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CAUTION
Power blending shall be accomplished so no excessive heat and
thermal stresses are generated. Failure to comply may result in part
damage.
(2) Hand-grind replacement vane to length of original vane +0.000 to -0.005 inch
(+0.00 to -0.13 mm). Maintain proper length and angle across vane tip. Stages
6-13 vanes have double angles on tip. Power tools may be used to shorten
grinding time but last 0.005 inch (0.13 mm) must be hand ground.
I. Install stage 13 stator vanes as follows (figure 31):
31
CAUTION
Use care so end-stop does not fall out of the liner segments and leaf
seals do not become disengaged.
(1) Install one end-stop and seven standard vanes into liner. Install vanes with
borescope cutouts into liner with borescope hole.
(2) With liner end-stop fully seated into liner slot, check position of last vane. Last
vane platform edge shall be 0.000-0.015 inch (0.00-0.38 mm) inside end of liner.
See figure 31. If end gap is not within limits, proceed as follows:
(a) Replace standard vanes with wide platform vanes, as required, to meet end
gap.
(b) Vane platform edges of replacement vanes may be ground a maximum of
0.006 inch (0.15 mm) per side to meet end gap. Surface finish and contour to
match original platform.
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Figure 31. Stage 13 Vane Installation (Sheet 1 of 2)
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Figure 31. Stage 13 Vane Installation (Sheet 2 of 2)
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(3) Remove seven stator vanes from liner and reinstall with spring retainers as
follows (figure 32):
CAUTION
• Make sure vane spring retainers are installed correctly. Spring
retainers can be installed inverted and may result in parts failure.
• Do not reuse vane spring retainers from a previously operated
engine. Failure to comply may result in part damage.
NOTE
Vane spring retainers are not installed under end vanes or
borescope vanes.
(a) Install new spring retainer behind platform edge of installed stator vane.
Ensure spring retainers are installed per figure 32.
(b) Install next stator vane until further movement requires force. Use nylon drift
or driver from compressor stator vane driver set, 2C6019, to drive against
vane platform, not airfoil. Drive stator vane over spring retainer until vane
platforms contact.
32
(c) Install remaining stator vanes per step (a) and (b) until all vanes are installed.
(d) Check that end gap is still within limits per step (2).
CAUTION
Do not allow thread lubricant on airfoil or case flowpath. Failure
to comply may result in part damage.
(4) Apply thread lubricant to rails of liners. Lubricant is not permitted on vane
airfoils or case flowpath.
(5) Position honeycomb seal in place with seal lip forward and install assembled liner
into stator case slots. Install remaining liners and install honeycomb seals to
bridge liner segments. Install honeycomb seal segments at horizontal flanges.
Install liner and honeycomb seal with borescope holes in bottom case, to align
with case borescope hole.
(6) Apply thread lubricant onto threads and washer faces of bolts. Secure liners with
bolts. Tighten bolts to 290-310 lb in. (32.8-35.0 N·m) of torque.
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Figure 32. Vane Spring Retainer Installation
(7) Check installation of liners as follows:
(a) Measure gap between liners, four places per HPC stator case half. Gap shall
not be less than 0.040 inch (1.02 mm).
(b) Measure gap between end liners and HPC stator case horizontal flange, two
places per case half. Gap shall not be less than 0.020 inch (0.51 mm).
(c) On lower HPC stator case, check that a 0.405-inch (10.29 mm) diameter rod
will pass freely through case, liner, and vane borescope holes.
(d) Loosen bolts and adjust position of liners, as required. Tighten bolts to
290-310 lb in. (32.8-35.0 N·m) of torque.
(8) Install borescope plug into lower HPC stator case as follows:
(a) Apply thread lubricant onto threads and washer face of borescope plug.
(b) Install plug and tighten to 95-105 lb in. (10.8-11.8 N·m) of torque. Safety-
wire plug.
J. Install stages 6-12 stator vanes as follows:
(1) On upper HPC stator case half, install retaining key on 3:00 o'clock horizontal
flange position and secure with two C-clamps (figure 33). On lower HPC stator
case half, install parallel bar on 3:00 o'clock horizontal flange position and secure
with two C-clamps.
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33
Figure 33. Stages 6-12 Stator Vanes Installation (Sheet 1 of 2)
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Figure 33. Stages 6-12 Stator Vanes Installation (Sheet 2 of 2)
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CAUTION
Do not allow thread lubricant on airfoil or case flowpath. Failure to com-
ply may result in part damage.
(2) Apply two thin coats of thread lubricant onto vane dovetails. Lubricant is not
permitted on vane airfoils or case flowpath.
(3) Install stages 7 and 11 stator vanes as follows:
CAUTION
If a scrap vane is used as a driver, ensure scrap vane is not installed. Fail-
ure to comply may result in part damage.
(a) Slide vane into retaining slot until flush against key or parallel bar. Use nylon drift
or compressor stator vane driver set, 2C6019, as required. Tool shall drive against
vane base, not airfoil. See figure 33.
(b) Continue installing vanes until all vanes are installed. Number of vanes per case half
shall comply with table 8.
Table 8. Stages 6-12 Vane Requirements
Vane Quantity Stage Minimum Platform Platform End Gap
(Per Stator Half) Width (Per Stator Half)
6* 32 1.293 in. (32.84 mm) 0.080-0.120 in. (2.03-3.05 mm)
7 36 1.134 in. (28.80 mm) 0.090-0.130 in. (2.29-3.30 mm)
8* 34 1.202 in. (30.53 mm) 0.105-0.145 in. (2.67-3.68 mm)
9* 38 1.073 in. (27.25 mm) 0.105-0.145 in. (2.67-3.68 mm)
10* 40 1.017 in. (25.83 mm) 0.115-0.155 in. (2.92-3.93 mm)
11 40 1.017 in. (25.83 mm) 0.120-0.160 in. (3.05-4.06 mm)
12* 42 0.989 in. (25.12 mm) 0.066-0.106 in. (1.68-2.69 mm)
* Vane platform gap requirements shall be met with vane retainers installed.
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(4) Install stages 6, 8, 9, 10, and 12 vanes as follows:
CAUTION
If a scrap vane is used as a driver, ensure scrap vane is not
installed. Failure to comply may result in part damage.
(a) Slide vane into retaining slot until flush against key or parallel bar. Use nylon
drift or compressor stator vane driver set, 2C6019, as required. Tool shall
drive against vane base, not airfoil. See figure 33.
CAUTION
• Make sure vane spring retainers are installed correctly. Spring
retainers can be installed inverted and may result in parts failure.
• Do not reuse vane spring retainers from a previously operated
engine. Failure to comply may result in part damage.
(b) Install new spring retainer behind platform edge of installed vane. Ensure
spring retainers are installed per figure 32.
(c) Install next vane into retaining slot until further movement requires force.
Use nylon drift or compressor stator vane driver set, 2C6019, to drive against
vane platform, not airfoil. Drive vane over spring retainer until vane
platforms contact figure 33.
(d) Install remaining vanes per steps (b) and (c) until all vanes are installed.
Install vanes with borescope platform cutouts, to align with HPC stator case
borescope holes. Number of vanes per case half shall comply with table 8.
(5) Check installation of borescope vanes as follows:
(a) On stages 6 and 10, check that a 0.405-inch (10.29 mm) diameter rod will
pass freely through HPC stator case and platform of vanes.
(b) On stage 12, check that a 0.320-inch (8.13 mm) diameter rod will pass freely
through HPC stator case and platform of vanes.
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K. Measure stages 6-12 vane total platform end-gap as follows:
(1) Push all vanes circumferentially toward retaining key or parallel bar, until no gaps
exist between vane platforms.
(2) Measure gap between last vane and case flange. Refer to table 1 for required
clearances. If end gap is not within limits of table 8, proceed as follows:
(a) Adjust quantity of wide and standard platform vanes to obtain required vane
platform end gap clearance. Each stage must contain quantity of vanes called
out in table 8.
(b) Vane platform edges of replacement vanes may be ground a maximum of
0.005 inch (0.13 mm) per side to meet end gap. See table 8 for minimum
platform widths. Surface finish and contour to match original platform.
L. Install vane retaining keys onto upper HPC stator case half flanges as follows:
(1) Install key onto each horizontal flange of upper HPC stator case half. Chamfered
side of key goes into case flange mating slot.
(2) Stake each key two places at each end and between adjacent vane slots between
stages 6 and 12. See figure 34.
(3) Using sharpening stone, remove any high metal caused by staking.
34
M. Install borescope plugs as follows:
(1) Apply thread lubricant to threads and washer face of borescope plug.
(2) Install plug into borescope port.
(3) Tighten IGV and stages 1 through 6 plugs to 95-105 lb in. (10.8-11.8 N·m) of
torque.
(4) Tighten stages 9, 10, 12, and 13 plugs to 95-105 lb in. (10.8-11.8 N·m) of torque.
Safety-wire or safety-cable plug.
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Figure 34. Top Case Vane Retainer Key Installation
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WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR (HPC) ROTOR
BLADES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 60
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 60 ..... 6
Alphabetical Index
Subject Page
Compressor Rotor Blades Blending ............................................................................................ 53
Compressor Rotor Blades Blending of Airfoil for Tip Erosion................................................... 56
Compressor Rotor Blades Concave and Convex Surfaces Blending .......................................... 56
Compressor Rotor Blades Leading and Trailing Edges Blending............................................... 56
Compressor Rotor Blades Tip Corner Blending.......................................................................... 59
Compressor Rotor Blades Tips Blending .................................................................................... 60
HPC Rotor Blade Replacement General Requirements .............................................................. 4
HPC Rotor Stage 1 Blades Inspection ......................................................................................... 7
HPC Rotor Stage 1 Blades Installation........................................................................................ 14
HPC Rotor Stage 1 Blades Removal ........................................................................................... 5
HPC Rotor Stage 1 Blades Selection........................................................................................... 13
HPC Rotor Stage 2 Blades Inspection ......................................................................................... 19
HPC Rotor Stage 2 Blades Installation........................................................................................ 29
HPC Rotor Stage 2 Blades Removal ........................................................................................... 18
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Alphabetical Index (cont)
Subject Page
HPC Rotor Stage 2 Blades Selection........................................................................................... 19
HPC Rotor Stages 3-14 Blades Inspection .................................................................................. 36
HPC Rotor Stages 3-14 Blades Installation................................................................................. 44
HPC Rotor Stages 3-14 Blades Removal .................................................................................... 31
HPC Rotor Stages 3-14 Blades Selection.................................................................................... 43
1. Introduction.
This work package contains instructions for inspecting, removing and installing high pressure compres-
sor (HPC) rotor blades.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Maintenance Considerations Chapter 11
Preventive Maintenance Chapter 12
High Pressure Compressor (HPC) Upper and Lower Stator WP 2411 00
Case Replacement
High Pressure Compressor Upper/Lower Stator Case SWP 2411 01
Opening/Closing
Illustrated Parts Breakdown GEK 105060
High Pressure Compressor Rotor Stages 1-5 Blade Clearance LM6000-IND-143
Increase (PA, PB, PC, and PD Models)
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3. Support Equipment.
Nomenclature Part No.
Prebend Tool, HPC Stage 1 Blade Retainer 2C6599G01
Seating Tool, HPC Stage 1 Blade Retainer 2C6600G03
Stop Install Tool, HPC Stage 2 Blade 2C6967G06
Retainer
Stop Removal Tool, HPC Stage 2 Blade 2C6968G02
Retainer
Removal Tool, HPC Stage 1 Blade Retainer 2C14198G02
Program, Balance - Blade Replacement 9446M61G02
(or latest CD-Rom version)
Fixture, Holding Local Mfg.
Wrench MSE-28
Removal Kit, HPC Rotor Locking Lugs 4013408-282G01 Local Mfg.
Contact Customer Support Manager
for copy of drawing
4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
Marking Pen Sharpie T.E.C.
(Black or Blue)
Penetrating Oil GE Spec
A50TF54, CL-A
(L1 Liquid Wrench)
Petrolatum Fed Spec VV-P-236
Silicone Rubber Adhesive GE Spec A15F6B6
(RTV 106)
Tape Local Purchase
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
None required.
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6. HPC Rotor Blade Replacement General Requirements.
NOTE
• An exception to this procedure is compliance with Service Bulletin
LM6000-IND-143, HPCR Stages 1-5 Blade Clearance Increase.
• The steel A-286 and titanium HPC spools have three locking slots
per stage in stages 6-9 and two locking slots per stage in stages 3-5
and stages 10-14. See figure 13 and figure 14. The new INCO 718
stages 3-9 HPC spool eliminated the locking slot, locking lug, and
two locking blades located 180 degrees circumferentially from the
loading slot on stages 6-9. Two standard blades per stage were
added to fill this gap. On the INCO 718 stages 3-9 HPC spool mea-
sure only one accumulative gap per stage and refer to table 6 and
table 7 for blade quantities and accumulated clearance require-
ments.
A. Up to 25 percent of all HPC rotor blades or three complete stages of blades can be replaced
using these procedures. If more blades require replacement, core engine replacement is
required.
NOTE
Position mark all blades and balance weights as removed. Any weights
removed must be position marked during removal.
(1) Return balance weights and unchanged blades, removed during replacement of blades, to
original locations.
(2) Damaged blades are replaced with blades of same pan weight where possible, within
following limits: for stages 1 through 3, within 0.5 grams; for stages 4 and 5, within
0.3 grams and for stages 6 through 16, within 0.2 grams. Replace heavily damaged
blades (with pieces missing) with blades of same part number.
B. Ten blades in rotor may be reworked to maximum repairable limits, if worked blades are dis-
tributed uniformly around circumference to reduce imbalance effects.
C. Blend up to 100 percent of blades locally for erosion at tips, if all blades in those stages are
blended by approximately same amount. It is recommended that equivalent of no more than
50 percent of stages be blended to minimum tip-chord erosion limits.
D. If an entire stage of blades require replacement, contact General Electric Customer Service to
obtain a set of preground blades.
E. Gain access to HPC rotor by removing top stator case per WP 2411 00 or by opening top sta-
tor case per SWP 2411 01.
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7. HPC Rotor Stage 1 Blades Removal.
NOTE
The No. 1 blade is at the same clock position as the stage 9 dovetail
loading slot.
A. Using marking pen, mark position of blades to be removed and corresponding dovetail
slot on stage 1 disk. If all stage 1 blades are being replaced, position mark No. 1 and
No. 5 dovetail slots on stage 1 disk.
B. Using retainer removal tool, 2C14198, remove stage 1 blade retainers of individual
blade to be removed and adjacent blades as follows (figure 1):
(1) Install seal protector over seals forward and aft of blades. Locally manufacture
protectors from plastic or rubber.
(2) Install aft clamp ring onto aft side of stage 1 disk.
(3) Install forward clamp ring onto forward side of stage 1 disk. Secure forward
clamp ring to aft clamp ring using handknobs.
CAUTION
Use care when straightening blade retainers to avoid scratching
stage 1 disk or damaging seal teeth.
(4) Using wedge-shaped edge of impact tool, bend forward tabs of retainers away
from blades. Straighten tabs using square edge of impact tool.
(5) Remove retainer removal tool from stage 1 disk.
(6) Use nylon bar and mallet to tap on forward tangs of blade retainer and force
retainer aft. Pull blade retainer from aft side of stage 1 disk. Discard blade
retainer.
CAUTION
Do not use tools or excessive force to remove blade(s), or blade
leading edge/trailing edge damage may occur.
C. Push blade to be removed and adjacent blades radially forward, to ease removal of
first blade. Do not remove adjacent blades from disk.
D. Push blade to be removed radially inward to disengage midspan shroud. Slide blade
forward out of stage 1 disk.
E. Pan weigh removed blades. Using marking pen, mark weight on blades.
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Figure 1. Stage 1 Blade Removal
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8. HPC Rotor Stage 1 Blades Inspection.
CAUTION
All stage 1 through 6 blades shall be kept together as engine sets; there are
different rotor grind methods used on HPC rotors, resulting in different
blade lengths for stage 1 through 6 blades.
A. There are different grind methods used on HPC rotors, resulting in different blade lengths for
stage 1 through 6 blades. Keep all stage 1 through 6 blades together as engine sets.
B. Visually inspect rotor stage 1 blades per table 1 and figures 2 and 3.
C. On gas turbines with SPRINT® system, stage 1 blades shall be replaced after 16,000 hours of
SPRINT® operation or as defined in Chapter 12, table 12-1, of this manual.
Table 1. HPC Rotor Stage 1 Blades Visual Inspection
2
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. All Areas (Except Squealer Tips) (figure 2) for:
a. Cracks Not serviceable Not repairable Replace blade
2. Area A (Critical) for:
a. Surface defects Any number, Any number, Blend per
0.003 inch (0.08 mm) 0.005 inch (0.13 mm) paragraphs 19 and 21
deep, if separated by deep, if separated by
0.1 inch (3 mm) 0.1 inch (3 mm)
3. Area B (Leading and Trailing Edges) for:
a. Dents Any number, 0.02 inch Any number within Blend per
(0.5 mm) deep, sepa- limits of Area B paragraphs 19 and 20
rated by 0.4 inch
(10 mm) of unaffected
material
NOTE
Shallow waviness at leading and trailing edges is normal and should
not be interpreted as a dent.
b. Nicks and Not serviceable Any amount within Blend per
scratches limits of Area B paragraphs 19 and 20
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Table 1. HPC Rotor Stage 1 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
4. Area C (Contours) for:
a. Nicks, dents, Any number, 0.005 inch (0.13 mm) Blend per
and pits 0.003 inch (0.08 mm) deep within 0.1 inch paragraphs 19 and 21
deep. Defects that are (3 mm) from edges.
opposite are permitted Remaining surfaces
providing opposing 0.010 inch (0.25 mm)
defects are not caused deep. Any number with
by same impact. A a minimum separation
defect 0.003 inch of 0.1 inch (3 mm) and
(0.08 mm) deep that no defects that are
shows through to oppo- opposite
site surface of the blade
is not serviceable
b. Scratches Any number, 0.005 inch (0.13 mm) Blend per
0.003 inch (0.08 mm) deep within 0.1 inch paragraphs 19 and 21
deep (3 mm) of edges.
Remainder of surfaces
0.010 inch (0.25 mm)
deep. Any number,
0.5 inch (13 mm) long,
with minimum separa-
tion of 0.1 inch
(3 mm) and no
opposing defects
5. Platforms for:
a. Nicks and Any number, Any number, Blend per
scratches 0.005 inch (0.13 mm) 0.010 inch (0.25 mm) paragraph 19
deep, any length deep, any length, with
0.1 inch (3 mm) sepa-
ration
b. Missing pieces Not serviceable Any amount Replace blade
6. Airfoil for:
a. Bent 0.100 inch (2.54 mm) Not repairable Replace blade
from original contour
along length of airfoil
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Table 1. HPC Rotor Stage 1 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Erosion Any amount, if tip Any amount, if tip Blend per
chord, measured chord, measured paragraphs 19 and 22. On
0.080 inch (2.03 mm) 0.080 inch (2.03 mm) gas turbines operating with
from tip, is not less from tip, is not less SPRINT® system, stage 1
than 2.36 inch than 2.36 inch blades shall be replaced
(59.9 mm) and thick- (59.9 mm) and thick- after 16,000 hours of
ness, measured ness, measured SPRINT® operation or as
0.030 inch (0.76 mm) 0.030 inch (0.76 mm) defined in
from trailing edge, is from trailing edge, is Chapter 12, table 12-1, of
not less than 0.010 inch not less than 0.010 inch this manual
(0.25 mm) (0.25 mm)
7. Area B (Tip Corners) for:
a. Out of contour Not serviceable Maximum blend radius Blend per
caused by soft must remove all defec- paragraphs 19 and 23
body damage tive material. Rework
can extend into areas B
and C, 0.040 inch
(1.02 mm) out of con-
tour
b. Bent or Not serviceable Any amount, if tip Blend per
damaged tip chord is not less than paragraphs 19 and 23
corners, tip 2.36 inch (59.9 mm)
curl, metal and thickness measured
missing from 0.030 inch (0.76 mm)
leading or from trailing edge, is
trailing edge tip not less than 0.010 inch
corner (0.25 mm)
8. Squealer Tip for:
a. Cracks, nicks, Not serviceable Any amount, Blend per
and dents 0.030 inch (0.76 mm) paragraphs 19 and 24, no
deep steps allowed
b. Heat discolora- Any color or amount Not repairable Replace blade
tion due to rub within 0.06 inch
(1.5 mm) of blade tip
c. Burrs and high Not serviceable Any amount Remove burrs and high
metal due to metal per
rub paragraphs 19 and 24
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Table 1. HPC Rotor Stage 1 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
d. Tip notches, Any amount. -- --
uniform, No action required
circular notches
in tip (usually
in 2-4 blades
per stage)
9. Dovetails and Tangs for:
a. Missing coating 5 percent of parent Not repairable Replace blade
metal exposed
b. Worn coating Any amount not to Not repairable Replace blade
parent metal
c. Dovetail parent Not serviceable Not repairable Replace blade
metal wear
d. Tang parent Not serviceable Not repairable Replace blade
metal wear
10. Midspan Shroud Interlock Surface Carboloy Wear Pad for (figure 3):
a. Chipped pad 10 percent of pad may Not repairable Replace blade
be missing
b. Cracked pad Not serviceable Not repairable Replace blade
c. Pad wear, Any amount, Not repairable Replace blade
smooth or 0.010 inch (0.25 mm)
stepped pad thickness remain-
ing
d. Missing pad Not serviceable Not repairable Replace blade
e. Wear into Not serviceable Not repairable Replace blade
midspan shroud
parent material
11. Midspan Shroud for:
a. Cracks Not serviceable Not repairable Replace blade(s)
b. Missing Not serviceable Not repairable Replace blade(s)
material
3
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Figure 2. HPC Rotor Stage 1 Blade Inspection Areas
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Figure 3. HPC Rotor Stage 1 Blade Mid Span Carboloy Wear Pad Inspection
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9. HPC Rotor Stage 1 Blades Selection.
NOTE
If individual blades are being replaced, obtain correct blade length per
step A. If all stage 1 blades are being replaced, proceed to step B.
A. If individual blades are being replaced, obtain correct blade length as follows:
(1) Select replacement blade with length equal to or slightly longer than blade being
replaced. Take measurement from bottom of blade dovetail. If replaced blade
length cannot be determined, use length of shorter of two adjacent blades or
0.005 inch (0.13 mm) less than longer blade, whichever is longer.
WARNING
Do not breathe the particles from grinding or let the particles
touch you. The particles can cause damage, injury, or irritation
to you. Use personal protection equipment. Use local mechanical
exhaust ventilation or an approved respirator.
CAUTION
Power blending shall be accomplished so no excessive heat and thermal
stresses are generated. Failure to comply may result in part damage.
(2) Grind replacement blade to correct length, as required. Power tools may be used
to shorten grinding time but last 0.005 inch (0.13 mm) must be hand worked.
(3) Etch hand worked area and spot-fluorescent-penetrant inspect per Chapter 11.
NOTE
Replacement blades shall be weighed after tip grinding.
B. Weigh replacement blades. Using marking pen, mark weight on blade. If all stage 1
blades are being replaced, record weights on blade position map, figure 4.
NOTE
If individual blades are being replaced, select blades per step C. If all
stage 1 blades are being replaced, calculate blade position per step D.
C. If individual blades are being replaced, select replacement blade within 0.5 gram of
original blade. Blades replacing those with portions missing shall weigh within
0.5 gram of the average of eight adjacent serviceable blades. If replacement blade
within 0.5 gram is not available, use blade replacement guide, figure 5.
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Figure 4. Stages 1-2 Blade Replacement Map
NOTE
For a copy of GE computerized balance program and instructions for use,
contact GE customer service.
D. If all stage 1 blades are being replaced, calculate blade position using GE computerized
balance program, 9446M61, Blade Plot. Mark blade position on blade map, figure 4.
10. HPC Rotor Stage 1 Blades Installation.
CAUTION
Do not use tools or excessive force to install blade(s), or blade leading
edge/trailing edge damage may occur.
A. Slide adjacent stage 1 blades part way out of disk. Slide blade to be reinstalled into corre-
sponding dovetail slot from forward side of stage 1 disk and engage midspan shrouds. Slide
all adjacent blades back into position.
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Figure 5. Stages 1-2 Blade Replacement Guide
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B. Lift adjacent blades and reinstalled blade radially outward and install new blade
retainers under blades, from aft side of disk. Ensure blade retainer is seated against aft
side of blade. Retainer may be pulled from forward end for proper seating. Do not
hammer on aft end of retainer.
NOTE
If all stage 1 blades are being replaced, proceed to step D.
C. If individual blades are being replaced, measure blade-tip-to-lower-stator-case
clearance as follows:
(1) Pull replacement blade and adjacent blades radially outward. Shake blade to
ensure blade is at most outward position.
(2) Measure clearance between adjacent blade tips close to replacement blade and
edge of lower case. Make same measurement for replacement blade. Ensure
replacement blade-tip-to-case measurement is the same or greater (more
clearance) than adjacent non-removed blades.
(3) Repeat steps (1) and (2) for each replacement blade.
D. Measure clearance between midspan shrouds as follows (figure 6):
NOTE
Round wooden toothpicks may be used as shims.
(1) Tap four wooden shims between each stage 1 blade retainer and disk. Two shims
under forward end of blade retainer and two shims under aft end.
(2) Ensure all blades are seated fully aft, with tangs against disk.
6
(3) Shine light through gap or use 0.001-inch (0.03 mm) shim to check for clearance
between midspan shrouds. Do not measure as cumulative gap. No clearance is
permitted. Replace stage 1 blade, as required, to eliminate clearance between
midspan shrouds.
(4) Remove wooden shims.
E. Using plastic bar, figure 7, hold blade retainer forward and prebend forward tabs using
pre-bend tool, 2C6599. Ensure tool is seated onto retainer tab prior to bending.
F. Position seating tool, 2C6600, onto stage 1 blade retainer tabs. Center forward foot of
tool radially between two retainers. Fit aft foot of tool over tabs of both retainers.
Ensure leg of seating tool marked FWD is on forward side of disk.
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Figure 6. Midspan Shroud Gap Check
WARNING
Serious injury can occur when applying hydraulic pressure. Eye
protection is required. Relieve pressure before disconnecting lines
and fittings.
G. Apply 5,000 psig (34,474 kPa gage) maximum hydraulic pressure to seating tool,
2C6600G03, to seat blade retainer tabs. If using seating tool, 2C6600G02, apply 8,000
psig (55,158 kPa gage) maximum hydraulic pressure to seat blade retainer tabs. Push aft
leg of seating tool forward while applying hydraulic pressure so retainer is correctly
seated while bending. Release hydraulic pressure and remove seating tool. Remove seal
protectors.
H. Inspect installation of stage 1 blade as follows:
(1) Using feeler stock, measure clearance between blade retainer and disk. Measure
clearance on both forward and aft side of disk. Total combined clearance shall not
exceed 0.025 inch (0.64 mm). Replace blade retainer if requirement is not met.
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Figure 7. Stage 1 Blade Retainer Installation
(2) After retainer is seated, check for axial movement of blade by hand. If blade
movement is detected, measure with dial indicator placed against blade platform
face. Movement shall not exceed 0.025 inch (0.64 mm). Replace blade retainer if
requirement is not met.
(3) Inspect retainer for cracks using light, inspection mirror, and 10X magnifying
glass. Pay particular attention to areas of bend radii. No cracks allowed.
11. HPC Rotor Stage 2 Blades Removal.
NOTE
The No. 1 blade is at the same clock position as the stage 9 dovetail
loading slot.
A. Using marking pen, mark position of blades to be removed and corresponding dovetail
slot on stage 2 disk. If all stage 2 blades are being replaced, position mark No. 1 and
No. 5 dovetail slots on stage 2 disk.
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B. Using retainer stop removal tool, 2C6968, remove stage 2 blade and retainer as
follows (figure 8):
8
(1) Position clamp rings between stages 1 and 2 disks. Turn three jackscrews to retain
clamp rings against disks and stage 2 blade retainers.
(2) Install anvil assembly aft of stage 2 blade so that lower anvil is under one leg of
retainer tab and upper anvil is placed on top of retainer stop.
(3) Tap down on upper anvil with plastic mallet until retainer stop is straightened.
(4) Remove all components of retainer stop removal tool, 2C6968.
(5) Using pliers, pull retainer stop from side of blade slot. See figure 9. Discard
retainer stop.
9
(6) Slide retainer to center of dovetail slot. Remove retainer and blade. If retainer is
not damaged, retain for installation.
C. Pan weigh removed blades. Using marking pen, mark weight on blades.
12. HPC Rotor Stage 2 Blades Inspection.
CAUTION
All stage 1 through 6 blades shall be kept together as engine sets;
there are different rotor grind methods used on HPC rotors, resulting
in different blade lengths for stage 1 through 6 blades.
A. There are different grind methods used on HPC rotors, resulting in different blade
lengths for stage 1 through 6 blades. Keep all stage 1 through 6 blades together as
engine sets.
B. Visually inspect stage 2 rotor blades per table 2, and figures 10 and 11.
13. HPC Rotor Stage 2 Blades Selection.
NOTE
If individual blades are being replaced, obtain correct blade length per
step A. If all stage 2 blades are being replaced, proceed to step B.
A. If individual blades are being replaced, obtain correct blade length as follows:
(1) Select replacement blade with length equal to or slightly longer than blade being
replaced. Take measurement from bottom of blade dovetail. If replaced blade
length cannot be determined, use length of shorter of two adjacent blades or
0.005 inch (0.13 mm) less than longer blade, whichever is longer.
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Figure 8. Stage 2 Blade Retainer Stop Removal
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Figure 9. Stage 2 Blade Installation
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Table 2. HPC Rotor Stage 2 Blades Visual Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. All Areas (Except Squealer Tips) (figure 10) for:
a. Cracks Not serviceable Not repairable Replace blade
2. Area A (Critical) for:
a. Surface defects Any number, Any number, Blend per
0.003 inch (0.08 mm) 0.005 inch (0.13 mm) paragraphs 19 and 21
deep, if separated by deep, if separated by
0.1 inch (3 mm) 0.1 inch (3 mm)
3. Area B (Leading and Trailing Edges) for:
NOTE
Shallow waviness at leading and trailing edges is normal and
should not be interpreted as a dent.
a. Dents Any number, 0.02 inch Any number within Blend per
(0.5 mm) deep, sepa- limits of Area B paragraphs 19 and 20
rated by 0.4 inch
(10 mm) of unaffected
material
b. Nicks and Not serviceable Any amount within Blend per
scratches limits of Area B paragraphs 19 and 20
4. Area C (Contour) for:
a. Nicks, dents, Any number, 0.005 inch (0.13 mm) Blend per
and pits 0.003 inch (0.08 mm) deep within 0.1 inch paragraphs 19 and 21
deep. Defects that are (3 mm) from edges.
opposite are permitted Remaining surfaces
providing opposing 0.010 inch (0.25 mm)
defects are not caused deep. Any number with
by same impact. Defect minimum separation of
0.003 inch (0.08 mm) 0.1 inch (3 mm) and no
deep that shows defects that are oppo-
through to opposite site
surface of blade is not
serviceable
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Table 2. HPC Rotor Stage 2 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Scratches Any number, 0.005 inch (0.13 mm) Blend per
0.003 inch (0.08 mm) deep within 0.1 inch paragraphs 19 and 21
deep (3 mm) of edges.
Remainder of surfaces
0.010 inch (0.25 mm)
deep. Any number,
0.5 inch (13 mm) long,
with minimum separa-
tion of 0.1 inch
(3 mm) and no
opposing defects
5. Platforms for:
a. Nicks and Any number, Any number, Blend per
scratches 0.005 inch (0.13 mm) 0.010 inch (0.25 mm) paragraph 19
deep, any length deep, any length, with
0.1 inch (3 mm) sepa-
ration
b. Missing pieces Not serviceable Any amount Replace blade
6. Tip Corners for:
a. Bent or Not serviceable Any amount if tip Blend per
damaged tip chord, measured paragraphs 19 and 23
corners, tip curl, 0.080 inch (2.03 mm)
metal missing from tip, is not less
from leading or than 2.36 inch
trailing edge tip (59.9 mm), and
corner trailing edge thickness
is not less than
0.010 inch (0.25 mm)
7. Squealer Tip for:
a. Cracks, nicks, Not serviceable Any amount, Blend per
and dents 0.030 inch (0.76 mm) paragraphs 19 and 24,
deep no steps allowed
b. Heat discolora- Any color or amount Not repairable Replace blade
tion due to rub within 0.06 inch
(1.5 mm) of blade tip
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Table 2. HPC Rotor Stage 2 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Burrs and high Not serviceable Any amount Remove burrs and high
metal due to rub metal per
paragraphs 19 and 24
d. Tip notches, Any amount. No action -- --
uniform, required
circular notches
in tip (usually
in 2-4 blades
per stage)
8. Dovetails and Tangs for:
a. Missing 5 percent of parent Not repairable Replace blade
coating metal exposed
b. Worn coating Any amount not to Not repairable Replace blade
parent metal
c. Dovetail parent Not serviceable Not repairable Replace blade
metal wear
d. Tang parent Not serviceable Not repairable Replace blade
metal wear
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Table 2. HPC Rotor Stage 2 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
9. Blade Airfoil Tip (figure 11) for:
a. Erosion Any amount, if tip Not repairable Replace blade
chord, measured
0.080 inch (2.03 mm)
from the tip, is not less
than 2.36 inches
(59.9 mm), and thick-
ness, measured
0.030 inch (0.76 mm)
from trailing edge, is
not less than 0.010 inch
(0.25 mm). On gas tur-
bines operating with
®
SPRINT system, record
chord length for each
stage 2 blade on blade
inspection record
(table 3). Blade No.1 is
at same clock position
as stage 9 dovetail
loading slot. Count
remaining blades
clockwise, ALF
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Table 3. HPC Blade Inspection Record
__________ Package Hours __________
Engine Serial Number
__________ ®
Date SPRINT Operating Hours __________
__________
Last Inspection Date TSPRHP __________ TSPRLP __________
Position Number Stage 2 Stage 3 Stage 4
Minimum Chord Measured 2.36 in. (59.9 mm) 1.59 in. (40.4 mm) 1.44 in. (36.6 mm)
0.080 in. (2.03 mm) down
from blade tip
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 N/A
28 N/A
29 N/A
30 N/A
31 N/A
32 N/A
33 N/A
34 N/A
35 N/A
36 N/A
37 N/A
38 N/A
39 N/A
40 N/A
41 N/A
42 N/A
43 N/A N/A
44 N/A N/A
45 N/A N/A
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Figure 10. HPC Rotor Stage 2 Blade Inspection Areas
Figure 11. HPC Rotor Stage 2 Blade Airfoil Tip Erosion
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WARNING
Do not breathe the particles from grinding or let the particles
touch you. The particles can cause damage, injury, or irritation
to you. Use personal protection equipment. Use local mechanical
exhaust ventilation or an approved respirator.
CAUTION
Power blending shall be accomplished so no excessive heat and
thermal stresses are generated. Failure to comply may result in part
damage.
(2) Grind replacement blades. Using marking pen, mark weight on blade. Power tools
may be used to shorten grinding time but last 0.005 inch (0.13 mm) must be hand
worked. See figure 4.
NOTE
Replacement blades shall be weighed after tip grinding.
B. Pan weigh replacement blades. Using marking pen, mark weight on blade. If all stage
2 blades are being replaced, record weights on blade position map. See figure 4.
NOTE
If individual blades are being replaced, select blades per step C. If
all stage 2 blades are being replaced, calculate blade position per
step D.
C. If individual blades are being replaced, select replacement blade within 0.5 gram of
original blade. Blades replacing those with portions missing shall weigh within
0.5 gram of average of eight adjacent serviceable blades. If replacement blade within
0.5 gram is not available, use blade replacement guide. See figure 5.
NOTE
For a copy of GE computerized balance program and instruc-
tions for use, contact GE customer service.
D. If all stage 2 blades are being replaced, calculate blade position using GE compute-
rized balance program, 9446M61. Mark blade position on blade position map.
See figure 4.
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14. HPC Rotor Stage 2 Blades Installation.
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
A. Clean stage 2 disk dovetail slots, blade retainers, and blade dovetails with isopropyl
alcohol. Allow to air dry for 15 minutes, minimum.
B. Install retainer into dovetail slot, centered, with shoulders toward disk ID and hooks
facing left, aft looking forward. See figure 9.
C. Install blade from forward side over retainer, and slide retainer to left, aft looking
forward (ALF). If blade cannot be installed by hand pressure, remove retainer and
replace with thinner retainer.
CAUTION
The aft end of the retainer stop shall extend beyond the aft end of
the retainer.
D. Install retainer stop, from forward side, on right side of retainer, ALF, with shoulder
toward disk ID. Ensure shoulder of retainer stop seats against forward side of disk. If
necessary, tap with nylon drift and nylon mallet to seat.
NOTE
If all stage 2 blades are being replaced, proceed to step F.
E. If individual blades are being replaced, measure blade-tip-to-lower-stator-case
clearance as follows:
(1) Pull replacement blade and adjacent blades radially outward. Shake blade to
ensure blade is at most outward position.
(2) Measure clearance between adjacent blade tips close to replacement blade and
edge of lower case. Make same measurement for replacement blade. Ensure
replacement blade-tip-to-case measurement is the same or greater (more
clearance) than adjacent non-removed blades.
(3) Repeat steps (1) and (2) for each replacement blade.
F. Secure stage 2 blade with retainer stop installation tool, 2C6967, as follows
(figure12):
(1) With tool stop separated from anvil, install tool so lever arm is under aft end of
retainer stop and anvil holds retainer stop forward face against disk. Install tool
stop to anvil.
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Figure 12. Stage Blade Retainer Stop Installation
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CAUTION
Ensure lever arm does not slip off retainer stop during bending
operation. Damage to engine parts could result.
(2) Use hand pressure to securely hold lever arm under retainer stop and pull lever
arm handle forward to bend retainer stop outward 30 degrees, minimum.
(3) Remove retainer stop installation tool, 2C6967.
G. Inspect installation of stage 2 blade as follows:
(1) After retainer is seated, check for axial movement of blade by hand. If blade
movement is detected, measure with dial indicator placed against blade platform
face. Movement shall not exceed 0.020 inch (0.51 mm). Replace blade retainer if
this requirement is not met.
(2) Inspect retainer for cracks using light, inspection mirror, and 10X magnifying
glass. Pay particular attention to areas of bend radii. No cracks allowed.
15. HPC Rotor Stages 3-14 Blades Removal.
A. Using marking pen, number all blades in affected stages, starting with first blade
clockwise, ALF, from dovetail loading slot.
NOTE
If locking lugs cannot be removed per step B, remove lugs per
step C.
B. Remove blades from stage requiring blade replacement as follows:
(1) Prepare stages 3-5 and 10-14 locking lugs for removal as follows (figure 13):
CAUTION
Do not use unauthorized penetrating oils, or corrosion and prema-
ture failure may result.
(a) Apply penetrating oil to setscrew in locking lugs.
(b) Using wrench, MSE-28, loosen setscrew until threads bottom on locking lugs
located on both sides of loading slot.
(c) Push locking lugs radially inward to bottom of dovetail slot. Locking lugs
will be sufficiently below surface of retaining slot to permit circumferential
movement.
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Figure 13. Stages 3-5 and 10-14 Blade Installation
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(2) Prepare stages 6-9 locking lugs for removal as follows (figure 14):
(a) Apply penetrating oil to setscrew in locking lugs.
(b) Using wrench, MSE-28, loosen setscrew until threads bottom, on locking lugs
located on both sides of loading slot and on locking lug located 180 degrees oppo-
site loading slot.
(c) Push three locking lugs radially inward to bottom of dovetail slot. Locking lugs will
be sufficiently below surface of retaining slot to permit circumferential movement.
CAUTION
Locking lug access hole, located 180 degrees from loading slot, shall be
taped to prevent locking lug reseating while moving blades, or part dam-
age may result.
NOTE
The INCO 718 stages 3-9 HPC spool has two locking lugs and four
locking blades per stage. The locking slots 180 degrees circumferen-
tially from the loading slot on stages 6-9 were eliminated. For INCO
718 stages 3-9 HPC spools, disregard step 15.B.(2)(d).
(d) Cover access hole of locking lug, located 180 degrees from loading slot, with tape
to prevent possible resetting of lug into locking slot when blades are moved.
CAUTION
• Do not use unauthorized penetrating oils, or corrosion and pre-
mature failure may result.
• Impact tools should not be used to move blades, because of potential
damage to blades and spool.
NOTE
Penetrating oil may be used on blade dovetails to aid removal of blades.
(e) Rotate entire stage of blades circumferentially (in either direction) approximately
one-half width of blade platform, until locking blade is in line with loading slot.
Blades may be moved by lightly tapping on blade airfoil base with plastic drift. Use
care not to distort or damage airfoil.
(f) Remove blade by pulling straight out of loading slot.
(g) Slide locking lug to loading slot and remove.
(h) Remove adjacent locking blade and locking lug per steps (d) and (e).
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Figure 14. Stages 6-9 Blade Installation
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CAUTION
Failure to identify balance weight positions may result in rotor
imbalance.
(i) Continue moving blades up to loading slot and removing. If installed, remove
seal plugs from between stages 3-5 blades. Discard seal plugs.
(j) Using marking pen, mark balance weights by position, so weights can be
installed at same position when replacement blades are installed.
C. Remove seized locking lugs using removal kit, 4013408-282, as follows:
(1) Before drilling, try using the shock bar to unlock the screw. Soak lug with L1
Liquid Wrench. Shock lug using shock bar, provided in kit, and a small ball peen
hammer.
(2) If step (1) fails, use an easy out to remove setscrew as follows:
(a) Find inscribed metal depth guide block, for easy out drilling, in kit.
Determine what color chuck extender to use, based on the stage being
worked.
(b) Insert smaller diameter drill bit into chuck extender and tighten extender.
Ensure proper depth by inserting bit into hole in depth guide that corresponds
to stage being worked.
(c) Drill into screw until bottom of extender touches lug.
(d) Use easy out extractor and remove screw.
(3) If step (2) fails, drill out threads down to locking feature and use easy out as
follows:
(a) Use inscribed depth guide block for thread clearing and find correct chuck
to use.
(b) Insert larger diameter drill bit and check depth using depth guide. Drill into
screw until bottom of chuck extender touches lug.
(c) Use easy out extractor to remove screw.
D. In stages 6-14, check and remove wire seals, if required, as follows (figures 13 and14):
(1) Measure gap between ends of wire seal. Maximum serviceable gap between wire
seal ends is 1.00 inch (25.4 mm). Check one gap per stage on stages 6-10 and
three gaps per stage on stages 11-14.
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(2) Remove and discard wire seal if gap is greater than 1.00 inch (25.4 mm).
16. HPC Rotor Stages 3-14 Blades Inspection.
CAUTION
All stage 1 through 6 blades shall be kept together as engine sets; there
are different rotor grind methods used on HPC rotors, resulting in dif-
ferent blade lengths for stage 1 through 6 blades.
A. Different grind methods used on HPC rotors, result in different blade lengths for stage 1
through 6 blades. Keep all stage 1 through 6 blades together as engine sets.
B. Visually inspect stage 3–14 rotor blades per table 4 and figures 15 through 18.
15
Table 4. HPC Rotor Stage 3-14 Blades Visual Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Area A (Concave and Convex Surfaces of Root Airfoil Panel) (figure 15) for:
a. Surface defects Any number, Any number, Blend per
0.003 inch (0.08 mm) 0.005 inch (0.13 mm) paragraphs 19 and 21
deep, if separated by deep, if separated by
0.1 inch (3 mm). No 1.0 inch (3 mm)
transverse nicks or
scratches permitted
b. Cracks Not serviceable Not repairable Replace blade
c. Cracks or sepa- Not serviceable Not repairable Replace all blades in
ration at root to stage containing defec-
platform tive blade
2. Area B (Leading and Trailing Edges of Airfoil Panel) for:
a. Dents Any number, Any amount within Blend per
0.020 inch (0.51 mm) limits of figure 16 paragraphs 19 and 20
deep with minimum
root radius of
0.020 inch (0.51 mm),
separated by 0.4 inch
(10 mm) of unaffected
material
b. Nicks and Not serviceable Any amount within Blend per
scratches limits of figure 16 paragraphs 19 and 20
c. Cracks Not serviceable Not repairable Replace blade
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Table 4. HPC Rotor Stage 3-14 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
3. Area C (Concave and Convex Surfaces of Airfoil Panel) for:
a. Nicks, dents, Any number, 0.005 inch (0.13 mm) Blend per
and pits 0.003 inch (0.08 mm) deep if less than 0.1 paragraphs 19 and 21
deep. Defects that are inch (3 mm) from
opposite are permitted edges. Other surfaces
as long as defects are may be 0.010 inch
not caused by same hit. (0.25 mm) deep. Any
Defect 0.003 inch number with a mini-
(0.08 mm) deep that mum separation of
shows through to oppo- 0.1 inch (3 mm) and no
site surface of blade is defects that are
not serviceable opposite
b. Scratches Any number, 0.005 inch (0.13 mm) Blend per
0.003 inch (0.08 mm) deep if within 0.1 inch paragraphs 19 and 21
deep (3 mm) of edges.
Remainder of surfaces
0.010 inch (0.25 mm)
deep. Any number with
minimum separation of
0.1 inch (3 mm)
c. Cracks Not serviceable Not repairable Replace blade
4. Tips for:
a. Nicks, dents, Not serviceable Any number, Blend per
and cracks 0.030 inch (0.76 mm) paragraphs 19 and 24
deep in stages 3-9,
0.020 inch (0.51 mm)
deep in stages 10-14
Any number if damage
does not extend below
squealer tip; 0.09 inch
(2.3 mm) from tip for
blade without squealer
tip
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Table 4. HPC Rotor Stage 3-14 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Pits Any number, Any number if remain- Blend per
0.003 inch (0.08 mm) ing material is paragraphs 19 and 24
deep, 0.005 inch 0.010 inch (0.25 mm)
(0.13 mm) in diameter, thick after blending
separated by 0.10 inch Any number if damage
(2.5 mm) does not extend below
squealer tip; 0.09 inch
(2.3 mm) from tip for
blade without squealer
tip
c. Tip clanging on Not serviceable Minimum tip thick- Blend per
convex side ness of 0.010 inch paragraphs 19 and 24
only (see (0.03 mm) after
figure 16) removal of defect
d. Erosion (see Any amount if tip Any amount if tip Blend per
figure 17) Chord Y, measured chord Y, measured paragraphs 19 and 22
0.080 inch (2.03 mm) 0.080 inch (2.03 mm)
from tip, is within from tip, is within
figure 17 limits and figure 17 limits and
thickness, measured thickness, measured
0.030 inch (0.76 mm) 0.030 inch (0.76 mm)
from trailing edge, is from trailing edge, is
0.010 inch (0.25 mm) 0.010 inch (0.25 mm)
or greater. On gas tur- or greater
bines operating with
®
SPRINT system, record
chord length for each
stage 3 and 4 blade on
blade inspection record
(table 3). Blade No.1 is
first blade clockwise,
ALF, from dovetail
loading slot. Count
remaining blades
clockwise, ALF
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Table 4. HPC Rotor Stage 3-14 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
e. Bent or Not serviceable Any amount if tip Blend per
damaged tip Chord Y is within paragraphs 19 and 23
corners, tip figure 17 limits and
curl, metal thickness, measured
missing from 0.030 inch (0.76 mm)
trailing edge tip from trailing edge, is
corner 0.010 inch (0.25 mm)
or greater
f. Heat discolora- Any color or amount Not repairable Replace blade
tion due to rub within 0.06 inch
(1.5 mm) of blade tip
g. Burrs and high Not serviceable Any amount Remove burrs and high
metal due to metal per
rub paragraph 19
h. Tip notches, Any amount. No action -- --
uniform, required
circular notches
in tip (usually
in 2-4 blades
per stage)
5. Entire Airfoil for:
a. Bent (see Note) 0.050 inch (1.27 mm) Not repairable Replace blade
out of contour over
entire length of airfoil
NOTE
Measure blade bending by placing a straight edge spanwise (platform
to blade tip on concave side of blade airfoil) and measuring distance
between blade tip and straight edge (figure 18). If blade has squealer
tip, take measurement near squealer tip, but not at squealer tip.
6. Platform Edges for:
a. Nicks and Not serviceable Any number, Blend per
scratches 0.005 inch (0.13 mm) paragraph 19
deep, 0.10 inch
(2.5 mm) length
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Table 4. HPC Rotor Stage 3-14 Blades Visual Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Fretting and Any amount if wear Not repairable Replace blade
wear does not extend into
airfoil root radius
c. Bent areas Not serviceable Not repairable Replace blade
7. Platform for:
a. Wear or 0.003 inch (0.08 mm) Not repairable Replace blade
damage on top deep, 0.050 inch
or bottom (1.27 mm) long or
diameter
b. Seal wire wear, 0.010 inch (0.25 mm) Not repairable Replace blade
stages 6-9 deep
(figure 15)
c. Seal wire wear, 0.005 inch (0.13 mm) Not repairable Replace blade
stages 10-14 deep
(figure 15)
8. Dovetails for:
a. Fretting, Not serviceable Not repairable Replace blade
galling, or wear
of parent metal
b. Cracks or Not serviceable Not repairable Replace blade
separation
c. Missing coating 5 percent of parent Not repairable Replace blade
(stage 3-9 metal exposed
blades only)
d. Worn coating Any amount not to Not repairable Replace blade
(stages 3-9 parent metal
only)
9. Dovetails Fillets for:
a. Damage Not serviceable Not repairable Replace blade
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Figure 15. HPC Rotor Stage 3-14 Blade Inspection Areas
Figure 16. MHPC Rotor Stage 3–7 Blade Airfoil Tip Clang - Area D
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Figure 17. HPC Rotor Stage 3-14 Blade Airfoil Tip Erosion
Figure 18. HPC Rotor Stage 3-14 Blades Bending Inspection
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17. HPC Rotor Stages 3-14 Blades Selection.
NOTE
If individual blades are being replaced, select blades per step A. If an entire
stage of blades is being replaced, calculate blade position per step B.
A. If individual blades require replacement, select replacement blades as follows:
(1) Select replacement blades with length equal to or slightly longer than blade being
replaced. Take measurement from bottom of blade dovetail. If replaced blade length can-
not be determined, use length of shorter of two adjacent blades or 0.005 inch (0.13 mm)
less than the longer blade, whichever is longer.
CAUTION
Blade part numbers shall be checked before installation. New blade must
have same part number as old blade or comparable number per Illus-
trated Parts Breakdown (IPB), GEK 105060.
(2) Select replacement blades of similar platform width distribution of removed blades.
Check that replacement blades have correct part number per IPB, GEK 105060.
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B. If entire stage of blades requires replacement, determine blade position as follows:
(1) Using marking pen, number all replacement blades, starting with two of four
locking blades and ending with last two locking blades.
(2) Pan weigh replacement blades and record weight on blade position map.
See figure 19.
NOTE
For a copy of GE computerized balance program and instructions for
use, contact GE customer service.
(3) Determine blade position using GE computerized balance program, 9446M61.
Record blade position on blade position map.
18. HPC Rotor Stages 3-14 Blades Installation.
A. If stages 6-10 wire seals have been removed, install as follows (figure 20):
(1) Cut wire seals to completely encircle applicable seal groove forward and aft of
dovetail slot.
(2) Install wire seals into grooves forward and aft of dovetail slot. Position wire seals
so seal end gaps are minimum of 2.00 inches (50.8 mm) away from dovetail
loading slot.
(3) Trim ends of wire seals so end gap is within limits of table 5. Remove burrs and
sharp edges so ends are smooth and blunt. Apply petrolatum, as required, to hold
wire seals in place.
(4) Install two blades into dovetail loading slot and move blades around rotor to seat
wire seals. Position blade approximately 1.00 inch (25.4 mm) from ends of wire
seals and ensure end gap is within limits of table 5.
(5) Remove two blades from dovetail slot and ensure wire seals are seated in grooves.
B. If stages 11-14 wire seals have been removed, install as follows (figure 20):
(1) Cut each wire seal into three sections, each 23.00-26.00 inches (584.2-660.4 mm)
long.
(2) Install wire seal segments into seal groove forward and aft of dovetail slot.
Position two wire seal segments so end gap between two segments is minimum of
2.00 inches(50.8 mm) away from dovetail loading slot. Position remaining wire
seal segment 180 degrees from blade loading slot.
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Figure 19. Stages 3-14 Blade Replacement Position Map
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Figure 20. Stages 6-14 Blade Wire Seal Installation
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(3) Trim ends of wire seal segments so each end gap is within limits of table 5. Remove
burrs and sharp edges so ends are smooth and blunt. Apply petrolatum, as required,
to hold seals in place.
(4) Install six blades into dovetail loading slot and move the blades all the way around
rotor to seat wire seals. Position blade approximately 1.00 inch (25.4 mm) from end
of each wire seal and ensure end gaps are within limits of table 5.
(5) Remove six blades from dovetail slot and ensure wire seals are seated in grooves.
Table 5. Stages 6-14 Wire Seal End Gap Limits
Stage Number End Gap Limit Number of Gaps
0.100-0.150 inch
6-9 1
(2.54-3.81 mm)
0.050-0.100 inch
10 1
(1.27-2.54 mm)
0.020-0.040 inch
11-14 3
(0.51-1.02 mm)
C. Install stages 3-14 blades as follows:
NOTE
• The steel A-286 and titanium HPC spools have three locking
slots per stage in stages 6-9 and two locking slots per stage in
stages 3-5 and stages 10-14. See figure 13 and figure 14.
• The new INCO 718 stages 3-9 HPC spool eliminated the
locking slot, locking lug, and two locking blades located
180 degrees circumferentially from the loading slot on
stages 6-9. Two standard blades per stage were added to fill
this gap. On the INCO 718 stages 3-9 HPC spool measure
only one accumulative gap per stage and refer to table 6 and
table 7 for blade quantities and accumulated clearance
requirements.
(1) Using marking pen, mark location of locking slots and loading slots on OD of spool
or disk. See figures 13 and 14. Locking slots will not be visible after blades are
installed.
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WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
(2) Clean dovetail slots with isopropyl alcohol to aid in blade installation.
(3) Install locking lug in stages 6-9 as follows:
(a) Install locking lug in locking slot located 180 degrees opposite loading slot.
See figure 14. Slope of locking lug top surface must follow slope of blade
platform.
NOTE
The stage number is marked on the base of each locking lug.
(b) Tighten locking lug setscrew as follows:
1 Check for acceptable setscrew running torque by turning setscrew
through self-locking feature of locking lug and measuring torque when
setscrew is within one turn of dovetail slot bottom.
2 If setscrew running torque falls below 4 lb in. (0.5 N·m), determine
setscrew breakaway torque. Replace locking lug and/or setscrew if break-
away torque is less than 3.5 lb in. (0.4 N·m) and repeat step (b)1.
3 Using wrench, MSE-28, tighten locking lug setscrew 8-9 lb in.
(0.9-1.0 N·m) of torque greater than running torque determined in step
(b)1.
4 After setscrew is properly torqued, make sure locking lug is flush with or
below top of blade platform. Replace locking lug and/or setscrew if lug
protrudes above blade platform.
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CAUTION
• Failure to install balance weights in required locations will result
in rotor imbalance.
• Impact tools should not be used to move blades, because of poten-
tial damage to blades and spool.
• Do not use unauthorized lubricants, or corrosion and premature
failure may result.
(4) In stages 6-9, install locking blade on each side of locking lug with blade platform
cutout facing locking lug. Check blade part number and install blades to fill stage
requirements of table 6. Maintain blades and balance weights in original locations or
as indicated by GE computer blade balance program, Bladeopt.
(5) In stages 3-5 and 10-14, check blade part number and install blades to fill stage
requirements of table 6. Maintain blades and balance weights in original locations or
as indicated by GE computer blade balance program, Bladeopt.
NOTE
Seal plugs are no longer installed between blade dovetails. Seal plugs
have been deleted.
NOTE
The stage number is marked on the base of each locking lug.
(6) After all standard blades (nonlocking) are installed, install one locking blade on
each side of loading slot, with platform cutout facing toward loading slot. Install
locking slug on each side of loading slot. Slope of locking lug top surface must fol-
low slope of blade platform.
(7) Align locking lugs with locking slots and turn setscrew to raise locking slots. If
locking blade platform overhangs locking slot and prevents locking lug
engagement, replace standard blades (nonlocking blades) with blades having more
narrow platforms until overhang condition is corrected.
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Table 6. Stages 3-14 Blade Quantity Requirements
Standard Blades Locking Blades
Stage Number Per Stage Per Stage (with platform cutout) Total Blades
A-286 / TI INCO 718 A-286 / TI INCO 718 Per Stage
3 38 38 4 4 42
4 41 41 4 4 45
5 44 44 4 4 48
6 48 50 6 4 54
7 50 52 6 4 56
8 58 60 6 4 64
9 60 62 6 4 66
10 62 - 4 - 66
11-14 72 - 4 - 76
(8) Tighten locking lug setscrew per step C.(3)(b).
(9) Measure total accumulated clearance between blade platforms as follows:
(a) In stages 3-5 and 10-14, measure total accumulated platform clearance as
shown in figure 13. Slide one locking blade against locking lug and slide
remaining blades against locking lug on opposite side of loading slot.
Accumulated clearance shall be within limits of table 7.
(b) In stages 6-9, measure total accumulated platform clearance two places on
each side of loading slot as shown in figure 14. Slide one locking blade against
the locking lug and slide remaining blades against locking lug 180 degrees
opposite loading slot. Accumulated clearance shall be within limits of table 7.
(10) Correct accumulated platform clearance, as required, by selectively replacing
nonlocking blades with blades that have wider or narrower platforms.
Replacement blades must weigh within 0.5 gram for stage 3, 0.3 gram for
stages 4 and 5, and 0.2 gram for stages 6-16 of removed blades.
(11) Check each blade for overlapping (shingling) of platforms. Replace any blade
that exhibits a tendency to overlap (shingle). Replacement blades must weigh
within 0.5 gram of removed blade.
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Table 7. Accumulated Platform Clearance Limits
Stage Minimum Maximum
Number A-286 / TI INCO 718 A-286 / TI INCO 718
0.001 inch 0.001 inch 0.010 inch 0.010 inch
3-5
(0.03 mm) (0.03 mm) (0.25 mm) (0.25 mm)
0.005 inch 0.010 inch 0.011 inch 0.030 inch
6
(0.13 mm)* (0.25 mm) (0.28 mm)* (0.76 mm)
0.021 inch
0.015 inch 0.030 inch 0.050 inch
7 (0.
(0.38 mm)* (0.76 mm) (1.27 mm)
mm)*
0.030 inch 0.060 inch 0.036 inch 0.080 inch
8
(0.76 mm)* (1.52 mm) (0.91 mm)* (2.03 mm)
0.045 inch 0.090 inch 0.051 inch 0.110 inch
9
(1.14 mm)* (2.29 mm) (1.30 mm)* (2.80 mm)
0.001 inch 0.010 inch
10-14 - -
(0.03 mm) (0.25 mm)
* Per 180 degrees segments, between locking lugs.
(12) Install last two locking blades as follows:
NOTE
Stages 3-5 and 10-14 have two locking lugs. Stages 6-9 have three locking
lugs.
(a) In stages 3-5 and 10-14, loosen locking lugs on both sides of loading slot and push
them to bottom of locking slots.
(b) In stages 6-9, loosen two locking lugs on both sides of loading slot and one located
180 degrees opposite loading slot, and push them to bottom of
locking slots.
CAUTION
Locking lug access hole, located 180 degrees from loading slot, shall be
taped to prevent locking lug reseating while moving blades, or part dam-
age may result.
(c) In stages 6-9, place tape over access hole for locking lug 180 degrees from loading
slot, to prevent lug from engaging slot while moving blades.
(d) Install locking blade with blade platform cutout facing a locking lug.
Change 6 51
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WP 2413 00
CAUTION
Impact tools should not be used to move blades, because of potential
damage to blades and spool.
(e) Move entire stage of blades circumferentially approximately one-half width
of blade platform and install last locking blade with blade platform cutout
facing locking lug.
(f) Move entire stage of blades circumferentially in opposite direction until
locking lugs are aligned with locking slots.
(13) Tighten locking lug setscrew per step C.(3)(b).
(14) Verify that locking blades between locking lugs can move freely and indepen-
dently of each other. If locking blades cannot be installed or if they are clamped
together by lugs, switch position of locking blades and lugs in order to find a
sequence of blades and lugs which allows free movement of locking blades
between lugs. Replacement blades must weigh within 0.5 gram for stage 3,
0.3 gram for stages 4 and 5, and 0.2 gram for stages6-16 of removed blades.
NOTE
There are three locking lugs in stages 6-9 and two locking lugs in
stages 3-5 and 10-14.
(15) Ensure all blade locking lugs are installed and tight.
52 Change 6
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19. Compressor Rotor Blades Blending.
See figures 21 through 23.
WARNING
An accumulation of titanium dust shall be treated as a fire hazard.
CAUTION
• Titanium parts shall not be blend repaired with tools such as grinding
wheels, files, stones, or emery cloths that have been used to repair
other types of metal. Stages 1 through 5 blades are titanium.
• Do not use silver or cadmium tools on titanium parts. When cadmium-
or silver-plated tools are used on titanium parts, particles of cadmium
or silver may become embedded in the titanium. At temperatures
above 500°F (316°C), the metals can cause embrittlement, resulting in
overstessed areas and possible cracking. Chrome-plated, nickel-plated
and unplated tools may be used on titanium parts.
NOTE
A “Boroblend” process is available with the capability of blending some cases of
HPC blades distress through the borescope port without removal of the top stator
case. This procedure requires use of special equipment and qualified and
approved personnel. A single, one-time borescope inspection of the repaired
blades is required 500 hours after blending by this process. Contact your Cus-
tomer Support Manager to request determination of the applicability of this pro-
cess.
A. Use smooth file, not over 8.0 inches (203 mm) long, or emery cloth to remove nicks and
dents when removal of considerable material is necessary. File or blend in longitudinal direc-
tion (parallel with airfoil length). Power tools may be used for initial heavy removal of mate-
rial such as excessive tip curl. Final blend and polish 0.020–0.030 inch (0.51–0.76 mm) must
be accomplished by hand.
Change 6 53
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WP 2413 00
Figure 21. Compressor Rotor Blade Reference Areas (Sheet 1 of 2)
CAUTION
All blend repair and polishing shall be done in direction parallel with the
blade leading or trailing edges. Do not use power tools for final polish or
finish blending.
B. Use medium stone on any areas which have been blended with file or emery cloth, and on
areas containing small nicks and dents.
C. Use fine emery cloth and/or fine abrasive stone to polish blended area until finish looks and
feels like original.
D. Blend leading edges to as near original configuration as possible. Blend trailing edges to
remove all sharp edges. See figure 22.
54 Change 6
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WP 2413 00
Figure 21. Compressor Rotor Blade Reference Areas (Sheet 2 of 2)
Change 6 55
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20. Compressor Rotor Blades Leading and Trailing Edges Blending.
NOTE
On stages 2 through 14 rotor blades, if both leading and trailing edges are
blended, the maximum material removed at the tip shall not exceed the
amount shown in figure 21, sheet 2.
A. Blend leading and trailing edges to within maximum repairable limits defined in
figure 21. Contour blended edges per figure 22.
B. When blending out cracks blend away enough material to remove the effect and
continue to blend an additional 0.015 inch (0.38 mm).
CAUTION
All blend repair and polishing shall be done in direction parallel with the
blade leading or trailing edges. Do not use power tools for final polish or
finish blending.
C. Power tools may be used to shorten time required to remove metal but hand bench last
0.005 inch (0.13 mm).
D. After blending, spot-fluorescent-penetrant-inspect per Chapter 11. No cracks allowed.
21. Compressor Rotor Blades Concave and Convex Surfaces Blending.
NOTE
Width of blend shall not exceed 50 percent of the blade chord (figure
21).
A. Blend in longitudinal direction, parallel with length of blade.
B. After blending, spot-fluorescent-penetrant-inspect per Chapter 11. No cracks allowed.
22. Compressor Rotor Blades Blending of Airfoil for Tip Erosion.
A. Blend stage 2 blades as follows:
(1) Blend airfoils to within limits in figure 23. Restrict blending to leading and trailing
edges outboard of area 3.2 inches (81 mm) above top of blade platform. Blend leading
edges only if required to meet section contour.
(2) After blending, minimum trailing edge thickness of 0.010 inch (0.25 mm) is required.
Minimum tip chord remaining is 2.33 inches (59.2 mm).
56 Change 6
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Figure 22. Compressor Blade Blending
Change 6 57
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Figure 23. Compressor Rotor Blade Repair Limits
58 Change 6
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(3) After blending, spot-fluorescent-penetrant-inspect per Chapter 11. No cracks allowed.
B. Blend stage 3 through 14 blades as follows:
(1) Blend airfoils to within limits in figure 23. Restrict blending to leading and trailing
edges outboard of area 3.2 inches (81 mm) above top of blade platform. Blend leading
edges only if required to meet section contour.
(2) After blending, minimum trailing edge thickness of 0.010 inch (0.25 mm) is required.
Minimum tip chord of Y inches is required.
(3) After blending, spot-fluorescent-penetrant-inspect per Chapter 11. No cracks allowed.
C. Blend stage 1 blades as follows:
(1) Blend airfoils to within limits in figure 21. Restrict blending to leading and trailing
edges outboard of area 2.50 inches (63.5 mm) above top of blade platform. Blend
leading edges only if required to meet section contour.
(2) After blending, minimum trailing edge thickness of 0.010 inch (0.25 mm) is required.
Minimum tip chord remaining is 2.439 inches (61.95 mm).
(3) No blending is allowed 0.50 inch (12.7 mm) above or below midspan shroud or on
midspan shroud within 0.50 inch (12.7 mm) of blade airfoil.
(4) After blending, spot-fluorescent-penetrant-inspect per Chapter 11. No cracks allowed.
23. Compressor Rotor Blades Tip Corner Blending.
A. Whenever possible, remove damage on leading and/or trailing edge corners by blending to
smooth radius. Remove as little metal as possible. Do not exceed limits of figure 23.
B. If both corners are damaged, blend out damage; do not exceed radius of 1/10 blade chord
length for each corner. If only one corner is damaged, blend out damage at leading or trailing
edge corner; do not exceed a radius of 1/10 blade chord length for each corner.
C. Any number of blades may be blended as described above.
Change 6 59
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24. Compressor Rotor Blades Tips Blending.
NOTE
This procedure may have been performed on blades that have been blended
to maximum limits on the leading and/or trailing edges and/or tip corners.
A. Accept tips bent less than 15 degrees if there are no cracks.
CAUTION
Do not straighten bent tips.
B. Remove tips bent over 15 degrees by blending. Do not exceed limits of figure 22.
C. Repair blend nicks, gouges, dents and cracks by removing damaged metal per
paragraph 19 and within limits of figure 21. Length of removal will be governed by
figure 22.
D. Cracks must be completely removed by blending. Spot-fluorescent-penetrant-inspect crack
repairs after blending per Chapter 11. No cracks or burrs allowed.
60 Change 6
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5WP 2412 00
WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR (HPC) STATOR
OUTLET GUIDE VANES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 16
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 15 ...... 0
16 Blank . . . . . . 0
Alphabetical Index
Subject Page
HPC Outlet Guide Vane (OGV) Removal .................................................................................. 4
HPC Outlet Guide Vane Visual Inspection ................................................................................. 6
HPC Outlet Guide Vane Blending .............................................................................................. 9
HPC Outlet Guide Vane Installation ........................................................................................... 12
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WP 2414 00
1. Introduction.
NOTE
HPC outlet guide vanes are located in the compressor rear frame.
This work package contains instructions for removing and installing the high pressure
compressor (HPC) stator outlet guide vanes.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Maintenance Considerations Chapter 11
High Pressure Compressor (HPC) Upper and Lower Stator SWP 2411 01
Case Opening/Closing
High Pressure Compressor (HPC) Rotor WP 2413 00
Blades Replacement
3. Support Equipment.
Nomenclature Part No.
Tool Set, Jackscrew 1C9150G02
4. Consumable Material.
Nomenclature Specification
Anti-Seize Compound Milk-of-Magnesia
(Unflavored)
Cloth, Abrasive Aluminum Oxide,
Various Grit
Marking Pen Sharpie T.E.C.
(Black or Blue)
Oil, Engine Lubricating MIL-L-23699
Stone, Abrasive Local Purchase
Stone, Sharpening Fed Spec SS-S-736
Tape, Masking Local Purchase
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Nomenclature Specification
Tape, Plastic NT-580, Patco
No. 110-50, or
Shurtape PC-623
Thread Lubricant GP460
5. Referenced Procedures.
Chapter 11 Hand Blending
Chapter 11 Marking of Parts
Chapter 11 Spot Fluorescent-Penetrant
Inspection
Chapter 11 Swab Etching Procedures
6. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Clip, Vane Liner 9232M47P01 4
7. SPD Information.
None.
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8. HPC Outlet Guide Vane (OGV) Removal.
A. Open upper or lower HPC stator case per SWP 2411 01.
B. Remove stage 14 and, if required, stage 13 blades to gain access to OGVs per
WP 2413 00.
C. Remove HPC OGVs as follows:
WARNING
Insulation blankets contain fiberglass. Do not inhale the fiber-
glass or let it touch you. Personal protective equipment required.
Allergen and irritant. Well-ventilated.
(1) Bend OGV liner clips down (radially inward). See figure 1.
(2) Unseat OGV liner assemblies from OGV liner rails in CRF assembly. Secure
OGVs into liners using masking tape at end of liner that is not keyed.
WARNING
Lubricating oil, MIL-L-26399: Combustible. Do not inhale,
ingest, or let this material touch you. Irritant. Personal protective
equipment required. Use mechanical exhaust ventilation - If not
available, use an approved respirator.
(3) Using No. 10-32 thread jackscrew, lubricated with oil, remove OGV liner
assemblies from CRF assembly one at a time.
(4) Remove liner clips and discard.
(5) Remove OGVs and dovetail liners from OGV liner.
(6) Remove four insulation blankets from between OGV liner rails in CRF assembly.
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1
Figure 1. Outlet Guide Vane Removal
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9. HPC Outlet Guide Vane Visual Inspection.
A. Visually inspect Outlet Guide Vanes per table 1 and figure 2.
Table 1. HPC Outlet Guide Vane Visual Inspection.
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Outlet Guide Vanes for:
a. Missing OGV Not serviceable Not repairable Replace vane or seg-
airfoils ment
b. All areas for:
(1) Cracks Not serviceable Not repairable Replace vane or seg-
ment
(2) Surface None allowed Any amount Remove deposits with
deposits fine emery cloth. No
scratches allowed
c. Areas A for:
(1) Nicks and Any number, 0.005 0.010 inch (0.25 mm) Repair per
scratches inch (0.13 mm) deep deep paragraph 10
after removal of high
metal
(2) Dents Any number, 0.010 Not repairable Replace vane or seg-
inch (0.25 mm) deep ment
d. Area B (leading and trailing edges) for:
(1) Nicks, pits 0.005 inch (0.13 mm) Within minimum Repair per
and deep Chord V for vane paragraph 10
scratches
(2) Dents Any number, 0.020 Within minimum Repair per
inch (0.51 mm) deep Chord V for vane paragraph 10
(3) Erosion of Any amount provided Any amount provided Repair per
airfoil at minimum root chord is minimum root chord is paragraph 10
dovetail V inches or greater, V inches or greater,
and leading and trailing and leading and trailing
edge thicknesses are edge thicknesses are
0.012 inch (0.30 mm) 0.012 inch (0.30 mm)
or greater or greater
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Table 1. HPC Outlet Guide Vane Visual Inspection.
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
e. Airfoil tip Not serviceable Any amount 0.060 inch Repair per
damage (1.52 mm) deep over paragraph 10
20% of OGVs
f. Vane platform for:
(1) Nicks and Any number 0.015 Not repairable Replace vane or seg-
scratches inch (0.38 mm) deep ment
other than after removal of high
dovetail metal
scratches
(2) Fretting Wear not into airfoil Not repairable Replace vane or seg-
root radius fillet ment
(3) Wear from 0.060 inch (1.52 mm) Not repairable Replace vane or seg-
retaining deep ment
key
(4) Buckled Any amount provided Not repairable Replace three-vane
three-vane difference in tip spac- segment
segments ing does not exceed
0.150 inch (3.81 mm)
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2
Figure 2. OGV Inspection Areas
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10. HPC Outlet Guide Vane Blending.
NOTE
Blending may be accomplished using either step A, B, or C.
A. Remove high metal by blending down to the machined surface. Use abrasive stones or
papers. Coarse grades of abrasive may be used for fast removal of metal. Then use a
fine grade abrasive for the finish.
B. Blend to remove damage with a fine file, abrasive cloth or abrasive stone as follows
(figure 3):
(1) Blend and polish in a longitudinal direction, parallel with the airfoil of the blades.
(2) The leading and trailing edge radius of the blend repaired area must conform to
the original contour with the airfoil of the blades (figure 4) .
(3) When blending on an area involving a radius, maintain the radius as specified or
as near as possible to the original radius.
(4) The finish must be 16-32 microinches (0.41-0.81 micrometer).
CAUTION
Power blending must be accomplished in such a manner that
no excessive heat and thermal stresses will be generated.
C. If a large or deep blend is required, blend to remove the damage with a slow speed
power tool to shorten the time required for repair as follows (figure 3):
(1) Blend and polish in a longitudinal direction, parallel with the airfoil of the blades.
(2) The leading and trailing edge radius of the blend repaired area must conform to
the original contour (figure 4) .
(3) When blending on an area involving a radius, maintain the radius as specified or
as near as possible to the original radius.
(4) The finish must be 16-32 microinches (0.41-0.81 micrometer).
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3
Figure 3. Outlet Guide Vane - Blending
10
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4
Figure 4. Leading and Trailing Edge Blending
11
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11. HPC Outlet Guide Vane Installation.
A. Assemble OGVs to liners (figure 5) as follows:
CAUTION
Do not force OGVs into liners. OGVs should assemble without addi-
tional force. If OGVs cannot be installed easily, check for correct
vane orientation.
NOTE
• All dimensions involving OGV key in liner are taken with key bot-
tomed in slot.
• Vanes that are to be reinstalled in the same casing from which
they were removed, should have been numbered sequentially to
permit reinstallation in the same circumferential location.
(1) Install forward and aft vane dovetail liners into OGV liner as follows:
(a) Install vane dovetail liners into OGV liner per figure 5.
(b) With OGV key bottomed into slot in OGV liner, push dovetail liners so liners
are against OGV key. Check vane dovetail liners are 0.005-0.050 inch
(0.13-1.27 mm) inside end of OGV liner.
(2) Install vanes into OGV liner as follows:
NOTE
The number of wide and narrow vanes is to be adjusted to obtain the
required gap between the liner and last vane installed.
(a) Install one 3-vane OGV segment into end opposite key of each liner and slide
to key end of liner.
(b) Install 25 OGVs into each of OGV liners. Ensure all vane leading edges are
forward.
(c) Check OGVs extend 0.000-0.012 inch (0.00-0.30 mm) beyond end of OGV
liner with vanes rotated against OGV key and with OGV key bottomed in slot
against OGV liner. Use alternate wide and narrow OGVs to achieve this
dimension.
(d) Secure OGVs in liners with plastic tape until ready for installation into CRF
assembly.
12
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B. Install OGV assemblies into CRF assembly (figure 5) as follows:
WARNING
Insulation blankets contain fiberglass. Do not inhale the fiber-
glass or let it touch you. Personal protective equipment required.
Allergen and irritant. Well-ventilated.
(1) Install four insulation blankets between OGV liner rails. Use adhesive tape to
hold insulation blankets in place. Do not align butt ends of insulation blankets
with butt ends of OGV liners.
(2) Locally crush insulation blanket at slots in CRF rail to permit engagement of key.
Tearing of insulation blanket skin is not permitted.
(3) Using OGV liner assemblies as guide, mark locations on CRF that require liner
clips. Use marking pen.
(4) Install one OGV liner clip onto each marked location. Prebend clip and snap into
place. Liner clip should protrude forward after installed over rail.
NOTE
Outboard forward hook of liner must not protrude axially forward of
CRF forward flange.
(5) Install each OGV liner assembly, engaging liner key into slot in CRF rail. Rotate
liner counterclockwise (before seating), forward looking aft, so key contacts slot
in CRF rail.
NOTE
Ensure that OGV liner clips protrude through slots of the OGV liner
assembly.
(6) Seat OGV liner assembly onto OGV liner rails by lightly tapping with plastic or
rubber mallet.
(7) Bend OGV liner clips outboard to secure OGV liner assembly into CRF. Tabs
must not protrude forward of CRF forward flange.
(8) Remove tape that secures OGV segments in liners.
(9) Check for radial looseness of OGV liner assemblies with 0.005 inch (0.13 mm)
feeler stock.
13
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WP 2414 00
(10) Assure forward liner does not protrude axially forward of CRF forward flange.
(11) Measure gap between adjacent liners at four locations. Minimum gap shall be
0.044 inch (1.12 mm).
(12) If gap between adjacent liners is less than minimum, verify liner key is in contact
with CRF rail slot. Obtain gap by reworking end of liner without key. Rework per
Chapter 11, Hand Blending
(13) Use feeler stock to verify minimum gap of 0.030 inch (0.76 mm) between OGVs
and CRF forward inner diffuser.
(14) If minimum gap between OGVs and CRF forward inner diffuser is less than
minimum, rework vane tips to obtain 0.030 inch (0.76 mm) clearance. Rework
vane tips per Chapter 11, Hand Blending.
C. Reinstall stages 13 and 14 HPC blades per WP 2413 00.
D. Close upper and lower HPC stator cases per SWP 2411 01.
14
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5
Figure 5. HPC Outlet Guide Vane Installation
15/(16 Blank)
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WP 2415 00
5
WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE COMPRESSOR (HPC) STAGE 11
CHECK VALVE - VALVE FLAPPER REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 10 ...... 0
Alphabetical Index
Subject Page
Valve Flappers Removal ............................................................................................................. 3
Valve Flappers Installation.......................................................................................................... 7
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WP 2415 00
1. Introduction.
This work package contains instructions to replace the worn or missing valve flappers, hinge pin,
and stop pin in the stage 11 check valve.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Maintenance Considerations Chapter 11
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
5. Referenced Procedures.
Chapter 11 Spot Fluorescent-Penetrant Inspection
Chapter 11 Blending Procedures
6. Expendable Material.
Nomenclature Specification
Wire, Weld, Inco 625 Inco 625 weld wire
(AMS 5837)
7. SPD Information.
Nomenclature Part No.
Flapper, Valve 1978M21P01
Pin, Hinge, AMS 5759 or AMS 5796 Local Manufacture
Pin, Stop, AMS 5759 or AMS 5796 Local Manufacture
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8. Valve Flappers Removal.
A. Remove hinge pin, stop pin, and worn valve flappers from check valve assembly as
follows (figure 1):
1
WARNING
Do not breathe the particles from blending or let the particles touch
you. The particles from blending can cause damage, injury, or irrita-
tion to you. Use personal protection equipment. Use local mechanical
exhaust ventilation or an approved respirator.
CAUTION
Do not remove parent material of the check valve housing during
blending. Removal of parental metal will damage the stage 11 check
valve assembly.
(1) Blend to remove welds from ends of hinge pin and stop pin (four locations) per
Chapter 11.
(2) Use pin punch and mallet to drive hinge and stop pins out of check valve housing.
(3) Remove valve flappers from check valve housing.
(4) Discard hinge pin, stop pin and valve flappers.
B. Inspect check valve housing as follows (figure 1):
(1) Measure stop pin hole diameter AF in flange.
(2) Measure hinge pin hole diameter AE in flange.
(3) If necessary, ream hinge pin hole or stop pin hole in flange to the correct diamter.
WARNING
Alcohol is flammable and toxic to the skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
C. Using isopropyl alcohol and a clean cloth, clean ID and OD flange surfaces of check valve
housing. Replace soiled cloth with new ones until cloth shows no dirt.
D. Spot-fluorescent-penetrant-inspect check valve housing flange, hinge and stop pin holes
and ID surfaces of housing flange where valve flappers are removed per Chapter 11.
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WP 2415 00
Figure 1. Stage 11 Check Valve Assembly (Sheet 1 of 3)
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WP 2415 00
Figure 1. Stage 11 Check Valve Assembly (Sheet 2 of 3)
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WP 2415 00
Figure 1. Stage 11 Check Valve Assembly (Sheet 3 of 3)
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WARNING
Alcohol is flammable and toxic to the skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
E. Using isopropyl alcohol and a clean cloth, clean ID and OD flange surfaces of check
valve housing. Replace soiled cloth with new ones until cloth shows no dirt.
F. Inspect for fluorescent penetrant under a black light, make sure no penetrant is seen on
part. Repeat step E. as necessary to remove fluorescent penetrant.
9. Valve Flappers Installation.
A. Manufacture replacement hinge pin and stop pin as follows:
(1) Measure dimension AA of check valve housing and record the dimension. Refer
to figure 1.
(2) Locally manufacture replacement hinge pin per figure 2.
2
(3) Locally manufacture replacement stop pin per figure 3.
3
B. Install replacement valve flappers, hinge pin, and stop pin into flange of check valve
assembly as follows (figure 1):
(1) Install two new valve flappers, P/N 1978M21P01, into flange and align hinges
with hinge pin hole.
(2) Install replacement hinge pin through flange housing and valve flappers hinges.
(3) Ensure dimension AB for hinge pin is within limits.
(4) Install replacement stop pin into flange housing.
(5) Ensure dimension AB for hinge pin is within limits.
(6) Ensure valve flappers open and close freely by gravitational force. The flapper
valves must not bind or stick.
(7) Ensure valve flappers seal against sealing surfaces of the flange.
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Figure 2. Replacement Hinge Pin
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Figure 3. Replacement Stop Pin
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WP 2415 00
WARNING
Do not weld if you are not approved (trained and qualified). Use
personal protection equipment and approved safety procedures.
(8) Weld the ends of hinge pin and stop pin at four locations. Use AMS 5837 weld
wire. Make sure pins do not extend more than 0.060 inch (1.52 mm) from check
valve housing.
NOTE
Ensure dimension AB is within limits before and after weld.
(9) Visually inspect welds using 10X magnifying glass and white light to verify that
welds provide an airtight seal that will not permit leakage from pin holes. No
ndications are permitted.
C. Spot-fluorescent-penetrant-inspect the four pin welds per Chapter 11. No indications
are permitted. The welds must provide an airtight seal that will not permit leakage
from pin holes.
D. Clean check valve assembly using a mild alkaline solution.
E. Inspect for fluorescent penetrant under a black light, make sure no penetrant is seen on
part. Repeat step D. as necessary to remove fluorescent penetrant.
F. Inspect check valve assembly. Make sure valve flappers operate freely. No binding in
open or closed position is permitted. Make sure that valve flappers seal against the
sealing face of check valve flange assembly.
10
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2510 00
0WP 2510 00
WORK PACKAGE
TECHNICAL PROCEDURES
COMBUSTION CHAMBER REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 12
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 12 ...... 6
Alphabetical Index
Subject Page
Combustion Chamber Installation .............................................................................................. 8
Combustion Chamber Removal .................................................................................................. 3
Change 6 1
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WP 2510 00
1. Introduction.
This work package contains instructions for removing and installing the combustion chamber.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
3. Support Equipment.
Nomenclature Part No.
Adapter, Lift - Combustor, Stage 1 or 2 1C9362G02
HPT Nozzle
Adapter, Lift - Combustor, Stage 1 or 2 2C14219G01
HPT Nozzle (Alternate to 1C9362G02)
Adapter, Lift - Install/Remove 2C14689G01
Fixture, Install/Remove - Combustor 2C14691G01
Gage, Immersion Depth - Igniter Plug 2C6613G01
Heat Gun Local Purchase
Lifteye (0.500-13UNC-2B Thread) Local Purchase
4. Consumable Material.
Nomenclature Specification
Beeswax Local Purchase
Lubricating Oil MIL-L-23699
Marking Pen Sharpies T.E.C.
(Black or Blue)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
None required.
2 Change 6
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WP 2510 00
6. Combustion Chamber Removal.
A. Remove igniter plugs as follows:
WARNING
Ignition system shall be inoperative for at least 2 minutes before discon-
necting ignition leads. Ignition system could be charged with lethal high
voltage.
CAUTION
• Ensure igniter plug adapter is restrained when loosening coupling nut.
Failure to comply may result in part damage.
• Igniter plug may fall out when ignition lead is disconnected.
(1) Disconnect ignition lead from igniter plug adapter. See figure 1. Momentarily ground
ignition lead to remove any residual electrical charge.
(2) Remove igniter plug and shims.
1
Figure 1. Igniter Plug and Lead
Change 6 3
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WP 2510 00
NOTE
Some engines may have only one igniter plug at 3:00 o'clock position
and a blank off plug at 5:00 o'clock position.
(3) Repeat steps (1) and (2) for the other igniter plug, or blank off plug at 5:00 o'clock
position.
B. Install removal fixture, 2C14691, as follows (figure 2):
2
(1) Remove eight screws and washers from forward face of ring. See section D-D.
(2) Back off eight screws on aft side of ring so that pins do not protrude through
forward face of ring. See section C-C.
(3) Loosen nine handknobs and adjust clamps to ensure pins will clear combustion
liner. See section A-A.
(4) Install lifteye into threaded hole at top vertical centerline of ring. Tighten lifteye to
420-510 lb in. (47.5-57.6 N·m) of torque.
(5) Connect an overhead hoist onto lifteye. Lift removal fixture into position on
compressor rear frame (CRF) aft flange. Pin on forward face of ring shall engage
hole at top vertical centerline of CRF.
(6) Install three guides and bolts. Secure guides against inner diameter of outer liner
by tightening bolts finger-tight. See section A-A.
(7) Adjust nine clamps so that pins engage in combustor outer liner. Tighten
handknob to lock ring into place. See section B-B.
C. Install lift adapter, 2C14689, as follows (figure 3):
3
(1) Using quick-release pin, attach lift adapter, 1C9362, onto lift adapter. Adjust
center of gravity (CG), as required.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(2) Connect an overhead hoist to horizontal lift fixture link. Raise lift adapter into
position on aft flange of combustor inner liner.
(3) Using six bolts, secure lift adapter to aft flange of combustor inner liner. Tighten
bolts to 55-70 lb in. (6.3-7.9 N·m) of torque.
4 Change 6
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WP 2510 00
Figure 2. Combustor Install/Remove Fixture, 2C14691 (Sheet 1 of 2)
Change 6 5
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WP 2510 00
Figure 2. Combustor Install/Remove Fixture, 2C14691 (Sheet 2 of 2)
6 Change 6
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WP 2510 00
Figure 3. Install/Remove Lift Adapter, 2C14689
Change 6 7
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D. Remove combustion chamber as follows:
(1) Turn eight screws in by hand to seat pins against CRF aft flange. See figure 2,
section C-C.
CAUTION
Use care when removing combustion chamber from CRF to avoid
damage to fuel nozzles.
(2) Tighten each screw 1/2 turn, in sequence, until combustion chamber disengages
from CRF.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(3) Remove combustion chamber and place onto bench, forward end down. Remove
tooling.
7. Combustion Chamber Installation.
A. Install installation fixture, 2C14691, as follows (figure 2):
(1) Remove eight screws and washers from forward face of ring.
(2) Back off eight screws on aft side of ring so that pins do not protrude through
forward face of ring.
(3) Loosen nine handknobs and adjust clamps to ensure pins will clear combustor
liner.
(4) Install lifteye in threaded hole at top vertical centerline of ring. Tighten lifteye to
420-510 lb in. (47.5-57.6 N·m) of torque.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(5) Place ring onto combustion chamber aft flange. TOP VERT CL scribe line shall
pass through notch at top vertical centerline of combustion chamber aft flange.
(6) Install three guides and bolts. Secure guides against inner diameter of outer liner
by tightening bolts finger-tight. See section A-A.
(7) Adjust nine clamps so that pins engage in combustor outer liner. Tighten
handknobs to lock ring in place. See section B-B.
8 Change 6
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WP 2510 00
B. Install lift adapter, 2C14689, as follows (figure 3):
(1) Position lift adapter onto combustor liner. Tube shall be positioned at top vertical center-
line.
(2) Using six bolts, secure lift adapter on combustor liner.
(3) Using quick-release pin, attach horizontal lift fixture, 1C9362, onto lift adapter. Adjust
CG, as required.
C. Install combustion chamber as follows:
WARNING
Use correct lifting equipment and techniques. Stay out from under sus-
pended loads to prevent injury.
(1) Connect an overhead hoist to horizontal lift fixture link. Lift and turn combustion cham-
ber to horizontal position. Align combustion chamber with CRF.
(2) Position swirlers in center of swirler cups. Apply a small amount of beeswax at two
places on each swirler to retain swirlers in position. See figure 4.
4
Figure 4. Combustor Swirlers
Change 6 9
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WARNING
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.
(3) Apply a light coat of lubricating oil to inner conical surface of each swirler.
(4) Inspect interior area of CRF for dirt and foreign material. No dirt or foreign
materials are allowed.
WARNING
Wear insulated gloves to prevent injury when handling hot parts.
(5) Carefully move combustion chamber forward into CRF aligning notch in outer flange
with pin in CRF aft flange rabbet. Ensure that igniter plug ferrules are aligned and that
swirlers pass over fuel nozzles. If difficulty is encountered, heat CRF aft flange using
heat gun.
(6) Install eight screws and washers through CRF aft flange into forward face of ring. See
figure 2, section D-D.
(7) Loosen handknobs and adjust clamps to disengage pins from outer liner. See
section A-A.
(8) Tighten each screw 1/2 turn, in sequence, until outer liner aft flange is flush with, or
slightly aft of, CRF aft flange aft face. See section D-D. Ensure that fuel nozzles are
engaged in swirler openings.
(9) Remove lift adapter and horizontal lift fixture.
(10) Connect an overhead hoist onto lifteye in installation fixture.
CAUTION
Ensure combustion chamber is supported when tooling is removed. Fail-
ure to comply may result in combustion chamber falling.
(11) Remove eight screws and washers. Remove installation fixture. Store screws and washers
in thread holes in ring.
(12) Install bolts through CRF aft flange with nuts and oversize washers to support combus-
tion chamber until stage 1 HPT nozzle is installed.
10 Change 6
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D. Install igniter plugs as follows:
(1) Determine number of shims required as follows (figure 5):
5
(a) Measure from outer surface of igniter plug adapter to outer surface of
combustor ferrule using immersion depth gage, 2C6613. Record as
dimension A.
(b) Refer to table 1 to determine number of shims required.
(2) Install required number of shims onto igniter plug.
(3) Install igniter plug into igniter plug adapter. See figure 1.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
CAUTION
Ensure igniter plug adapter is restrained when tightening coupling
nut. Failure to comply may result in part damage.
(4) Install ignition lead over igniter plug adapter. Tighten coupling nut to 23-27 lb ft
(31.2-36.6 N·m) of torque. Safety-wire coupling nut.
Change 6 11
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Figure 5. Igniter Plug Immersion Depth
Table 1. Determine Number of Igniter Plug Shims Required
Dimension A Number of Shims Required
2.177-2.208 inch (55.30-56.08 mm) 0
2.145-2.176 inch (54.48-55.27 mm) 1
2.113-2.144 inch (53.67-54.46 mm) 2
2.081-2.112 inch (52.86-53.64 mm) 3
2.048-2.080 inch (52.02-52.83 mm) 4
2.016-2.047 inch (51.21-51.99 mm) 5
1.984-2.015 inch (50.39-51.18 mm) 6
1.952-1.983 inch (49.58-50.37 mm) 7
1.920-1.951 inch (48.77-49.56 mm) 8
12 Change 6
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WP 2511 00
5WP 2511 00
WORK PACKAGE
TECHNICAL PROCEDURES
STAGE 1 HIGH PRESSURE TURBINE (HPT) NOZZLE
REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 22
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 22 ...... 0
Alphabetical Index
Subject Page
High Pressure Rotor Bracket Installation.................................................................................... 13
High Pressure Rotor Bracket Removal ....................................................................................... 13
No. 5R Bearing Air/Oil Seal and No. 5R Bearing Housing Removal ........................................ 8
No. 5R Bearing Air/Oil Seal Installation .................................................................................... 19
No. 5R Bearing Housing and Oil Shield Installation.................................................................. 15
Nut Assembly (Gang Channel) Installation ................................................................................ 22
Nut Assembly (Gang Channel) Removal.................................................................................... 22
Stage 1 HPT Nozzle Installation ................................................................................................. 19
Stage 1 HPT Nozzle Removal..................................................................................................... 4
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WP 2511 00
1. Introduction.
A. This work package contains instructions for removing and installing the stage 1 high pressure
turbine (HPT) nozzle.
B. Remove the HPT module to gain access per WP 2610 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
High Pressure Turbine (HPT) Module Replacement WP 2610 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
NOTE
Accomplishment of this work package requires a 6-inch and 12-inch
parallel bar and a 0-18 inch vernier depth gage.
Nomenclature Part No.
Tool Set, Jackscrew - Disassemble 1C6804G04
Flanges
Tool Set, Jackscrew 1C9150G02
Adapter, Lift - Combustor, Stage 1 or 2 1C9362G02
HPT Nozzle
Adapter, Torque 2C14290G01
Fixture, Lift - Stage 1 HPT Nozzle 2C14695G01
Assembly
Slave Nuts (Qty 12, 0.375-24 thread) Local Purchase
Heat Gun Local Purchase
Rivet Squeezer Local Purchase
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Marking Pen Sharpie T.E.C.
(Black or Blue)
Petrolatum Fed Spec VV-P-236
Thread Lubricant GE Spec A50TF201
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WP 2511 00
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
A. Required Material
Nomenclature Part No. Qty
Ring, Piston 1754M91P01 6
Ring, Piston 1754M91P02 (ALT)
Screw, Machine 9186M93G04 132
Ring, Piston 9693M18P06 (ALT)
B. The following material may be required in the conduct of this work package.
GE recommends that the following material be available:
Nomenclature Part No. Qty
Seal, O-ring (A/O seal) 1375M50P03 1
Seal, O-ring (5R housing) 1375M50P04 1
Nut, Plain Round 9232M78P03 54
Nut Assembly, Self-locking (nozzle support) 9232M90P17 6
Nut Assembly, Self-locking (mini nozzle) 9232M90P18 6
Bolt, Slab-Head 9234M17P05 54
Rivet, Solid AN123631 18
Packing, Preformed (lube nozzle) J221P010 1
Bolt (5R A/O seal) J646P61B 6
Nut (mini nozzle support) J979P06 54
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6. Stage 1 HPT Nozzle Removal.
A. Remove aft air seal as follows (figure 1):
1
WARNING
Use thermal gloves when you move or touch hot or cold parts.
Hot or cold parts can cause injury.
(1) Remove 60 screws that secure aft air seal onto stationary seal support. If
necessary, heat screws using heat gun to facilitate removal.
(2) Remove 72 screws that secure air cover baffles and aft air seal onto stage 1 nozzle
support. If necessary, heat screws using heat gun to facilitate removal. Remove 24
air cover baffles and aft air seal.
B. Remove stationary seal support as follows (figure 2):
2
(1) Using marking pen, position mark top vertical centerline on stationary seal
support outer flange aft face.
(2) Remove 54 nuts that secure stationary seal support onto nozzle support inner
mounting flange. Use flex or universal joint on socket or torque adapter, 2C14290,
to prevent out-of-position stress on studs.
CAUTION
Uneven removal of stationary seal support may cause binding and
damage to recoup tubes and tube brackets. The following removal
sequence shall be followed to prevent binding and tube damage.
(3) Remove stationary seal support as follows:
(a) Coat threads of jackscrews, 1C6804, with thread lubricant. Install three
equally spaced jackscrews into inner mounting flange of stationary seal
support. Run in jackscrews until they contact compressor rear frame (CRF)
inner seal support flange.
(b) Screw in each jackscrew three turns.
(c) Repeat step (b) until stationary seal support is free of CRF.
(4) Remove six piston rings from recoup tubes. Discard piston rings.
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Figure 1. Aft Air Seal
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Figure 2. Stationary Seal Support (Sheet 1 of 2)
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Figure 2. Stationary Seal Support (Sheet 2 of 2)
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C. Remove stage 1 HPT nozzle as follows:
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
(1) Position lift fixture, 2C14695, at aft end of stage 1 HPT nozzle using lift adapter,
1C9362, and an overhead hoist. See figure 3. Secure lift fixture onto stage 1
nozzle support using eight screws provided with lift fixture. Tighten screws to
55-70 lb in. (6.3-7.9 N·m) of torque. Adjust center of gravity (CG) as required.
3
(2) Remove 30 bolts that secure stage 1 nozzle support onto combustor inner liner aft
support flange. See figure 4.
4
CAUTION
Do not install jackscrews in stage 1 nozzle support mid flange bolt
circle to remove stage 1 HPT nozzle. Failure to comply may cause
distortion of combustor inner liner aft support flange.
(3) Coat threads of jackscrews, 1C6804, with thread lubricant. Install three equally
spaced jackscrews into nozzle support inner mounting flange of stage 1 nozzle
support. Tighten jackscrews evenly, in small increments, to release stage 1 HPT
nozzle.
(4) Lift stage 1 HPT nozzle clear of engine.
7. No. 5R Bearing Air/Oil Seal and No. 5R Bearing Housing Removal.
A. Remove No. 5R bearing air/oil seal as follows (figure 5):
5
(1) Remove safety wire and remove 18 bolts that secure No. 5R bearing air/oil seal
and No. 5R bearing housing assembly onto aft sump.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(2) Using 0.250-28 thread jackscrews, 1C6804P04, lubricated with lubricating oil,
remove No. 5R bearing air/oil seal from No. 5R bearing housing.
(3) Remove and discard preformed packing from ring groove in forward end of
No. 5R bearing air/oil seal.
8
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Figure 3. Stage 1 HPT Nozzle Assembly Lift Fixture, 2C14695
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Figure 4. Stage 1 HPT Nozzle
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Figure 5. No. 5R Bearing Air/Oil Seal and No. 5R Bearing Housing Removal
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B. Remove No. 5R bearing housing as follows:
CAUTION
To preclude handling damage, it is important to remove the lube
manifold prior to removal of the bearing housing from the sump.
(1) Remove safety wire and remove three bolts and two clamps that secure
No. 5R bearing lube manifold onto No. 5R bearing housing.
(2) Remove lube manifold and discard preformed packing.
(3) Remove safety wire and remove seven bolts that secure No. 5R bearing oil shield
onto No. 5R bearing housing. Remove oil shield.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
CAUTION
Take care during the removal of the No. 5R bearing housing to prevent
shifting aft of the aft sump housing and unseating of the sump joint
piston ring. Use the following jackscrew procedure to assure that the
aft sump housing is not disturbed.
(4) Using 0.375-24 thread jackscrews, 1C9150P04, and 0.250-28 thread jackscrews,
1C6804P04, lubricated with lubricating oil, remove No. 5R bearing housing as
follows:
(a) Install 0.375-24 thread jackscrews, 1C9150P04, into jackscrew holes in
bearing housing inner flange. Turn screws until they contact aft flange of
sump housing, then tighten each screw three revolutions.
(b) Install 0.250-28 thread jackscrews, 1C6804P04, into jackscrew holes in
bearing housing outer flange. Turn screws until they contact CRF inner
flange, then tighten each screw three revolutions.
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NOTE
By tightening the jackscrews in the bearing housing inner flange
first, forward pressure is kept on the aft sump housing.
(c) Continue tightening jackscrews in sequence specified [step (a) then step (b)],
tightening jackscrews three revolutions each time, until No. 5 bearing
housing is free.
(5) Remove and discard preformed packing from outer diameter of No. 5 bearing
housing.
8. High Pressure Rotor Bracket Removal.
A. Remove brackets from CRF as follows (figure 6):
6
CAUTION
Use care in removing bolts and nuts. Do not drop bolts and nuts
into CRF, or CRF damage could result.
(1) Remove 12 slab-head bolts, nuts, and six high pressure rotor (HPR) brackets from
CRF aft inner flange.
(2) Remove remaining 42 slab-head bolts and nuts from CRF aft inner flange.
9. High Pressure Rotor Bracket Installation.
See figure 6.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
A. Lubricate threads and mate faces of slab-head bolts and nuts with lubricating oil.
B. Install brackets by inserting slab-head bolts through bracket and forward side of
flange. Flat side of bolthead fits against inside diameter of inner casing.
C. Thread nuts onto slab-head bolts and hand-tighten. No torque required.
13
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Figure 6. HPR Bracket Removal/Installation
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10. No. 5R Bearing Housing and Oil Shield Installation.
See figure 7.
7
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
A. Apply lubricating oil onto No. 5R bearing housing.
WARNING
Use thermal gloves when you move or touch hot or cold parts.
Hot or cold parts can cause injury.
B. Using heat gun, heat aft end of CRF assembly aft sump.
C. Coat preformed packing with lubricating oil. Install packing into ring groove of
No. 5R bearing housing.
D. Install No. 5R bearing housing into CRF assembly. Align clearance hole in housing
with No. 5R bearing forward lube nozzle in CRF assembly at approximately
10:00 o'clock position, aft looking forward.
E. Seat No. 5R bearing housing assembly as follows:
(1) Install six nuts onto equally spaced bolts on outer flange of bearing housing. Run
nuts down until they contact flange face.
(2) Install six bolts, equally spaced, into inner flange of bearing housing. Run bolts
down until they touch flange face.
(3) Turn nuts three turns each, then turn bolts three turns each.
(4) Repeat step (3) until bearing housing assembly is seated. Tighten bolts to
355 lb in. (40.1 N·m) and nuts to 225 lb in. (25.4 N·m) of torque. Remove nuts
and bolts.
15
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Figure 7. No. 5R Bearing Housing and Air/Oil Seal Installation
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CAUTION
• To assure proper assembly, lube manifold shall be installed
after the bearing housing is fully seated in sump.
• Make sure the preformed packing is properly installed to the
lube manifold and that the manifold is all the way in the hole of
the nozzle. Hold the manifold in place while securing with
bolts. Failure to comply may result in part damage.
F. Install lube manifold as follows (figure 7):
(1) Install two clamps onto lube manifold.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated
or prolonged contact. Use in a well-ventilated area.
(2) Coat preformed packing with lubricating oil. Install preformed packing onto end
of lube manifold.
(3) Insert end of lube manifold and preformed packing into forward No. 5R lube
nozzle. Align lube manifold clamps and mounting pad to three lugs on aft side of
bearing housing. Clamps are attached at two top lugs with flat of clamps aft.
(4) Hold lube manifold into forward No. 5 lube nozzle and secure with three bolts.
Check drop between aft face of housing and aft side of tube. Check drop at
clamps and near bend in tube where it turns forward. Maximum drop between aft
face of housing and aft side of tube is 0.290 inch (7.366 mm).
(5) Tighten three bolts to 33-37 lb in. (3.8-4.1 N·m) of torque and safety-wire.
G. Check lube nozzles as follows:
(1) Place petrolatum onto No. 5R bearing rollers, opposite lube nozzle.
(2) Connect dry air supply to oil inlet fitting located on No. 8 strut.
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WARNING
Serious injury can occur when applying pneumatic pressure. Eye
protection is required. Relieve pressure before disconnecting
lines and fittings.
(3) Pressurize manifold and check for impingement on bearing rollers. If jet doesn't
impinge on bearing rollers, loosen, adjust, and retighten lube manifold.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(4) Check for leakage where lube manifold plugs into forward jet by applying
lubricating oil to fitting. No leaks allowed
(5) Remove pressure and remove air supply.
H. Install No. 5R bearing oil shield as follows (figure 7):
(1) Install No. 5R bearing oil shield onto aft face of No. 5R bearing housing with
cutouts around clamps of lube manifold.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area
(2) Apply lubricating oil to threads of seven No. 5R bearing oil shield bolts. Secure
oil shield with bolts.
(3) Tighten seven bolts to 33-37 lb in. (3.8-4.1 N·m) of torque and safety-wire.
18
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11. No. 5R Bearing Air/Oil Seal Installation.
See figure 7.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
A. Coat preformed packing with lubricating oil. Coat threads of 18 bolts with thread
lubricant.
B. Install preformed packing into ring groove at forward end of No. 5R bearing air/oil
seal.
C. Install No. 5R bearing air/oil seal over No. 5 bearing housing assembly, aligning top
centerlines. Use drift pin to align holes in seal with holes in bearing housing.
D. Apply lubricating oil to threads of No. 5R bearing air/oil seal bolts and secure air/oil
seal with bolts. Tighten bolts alternately to 340-360 lb in. (38.5-40.6 N·m) of torque
and safety-wire bolts in groups of two.
12. Stage 1 HPT Nozzle Installation.
CAUTION
Ensure stage 1 HPT nozzle part number is correct per IPB, GEK
105060 before installation or damage to engine could result.
A. Check slab-head bolts for security. See figure 4. Tighten nut to 20-40 lb in.
(2.3-4.5 N·m) of torque if bolt is loose.
B. Install stage 1 HPT nozzle as follows:
(1) Position lift fixture, 2C14695, onto aft end of stage 1 HPT nozzle using lift
adapter, 1C9362, and an overhead hoist. See figure 3. Secure lift fixture to stage 1
nozzle support using eight screws provided with lift fixture. Tighten screws to
55-70 lb in. (6.3-7.9 N·m) of torque. Adjust CG as required.
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
(2) Lift stage 1 HPT nozzle into position on combustor. See figure 4. Align three
equally spaced holes in stage 1 nozzle support with those at top vertical centerline
of combustor. Borescope vane shall be at 4:30 o'clock position.
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(3) Seat stage 1 nozzle support onto No. 5 bearing housing using 12 equally spaced
slave nuts. Tighten nuts alternately, and evenly, until all nuts are seated. Tighten
nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
(4) Apply thread lubricant onto washer faces and threads of 30 bolts that secure stage
1 nozzle support onto combustor inner liner aft support flange.
(5) Install 30 bolts that secure stage 1 nozzle support onto combustor inner liner aft
support flange. Tighten bolts to 110-120 lb in. (12.5-13.5 N·m) of torque.
(6) Verify that outer leaf seals (360 degree radius) extend past combustor lip.
See figure 8.
(7) Remove 12 slave nuts.
(8) Remove lift fixture.
8
Figure 8. Outer Leaf Seals Check
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C. Install stationary seal support as follows (figure 2):
(1) Apply generous amount of thread lubricant onto bottom of bolthole counterbores
in forward flange of stationary seal support.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(2) Apply light coat of lubricating oil onto six new piston rings, P/N 1754M91P01.
(3) Install piston rings on recoup tubes.
WARNING
Use thermal gloves when you move or touch hot or cold parts.
Hot or cold parts can cause injury.
(4) Heat forward flange of stationary seal support using heat gun.
(5) Install stationary seal support, aligning position mark made at removal with top
vertical centerline of CRF.
(6) Apply thread lubricant onto threads of 54 nuts.
(7) Secure stationary seal support to nozzle support inner mounting flange using 54
nuts. Use flex or universal joint on socket or torque adapter, 2C14290, to prevent
out-of-position stress on studs. Tighten nuts alternately, and evenly, to seat
stationary seal support. Tighten nuts to 400-450 lb in. (45.2-50.8 N·m) of torque.
D. Install aft air seal as follows (figure 1):
(1) Install aft air seal onto stationary seal support so part number is at 12:00 o'clock
position.
(2) Apply thread lubricant onto washer faces and threads of screws that secure aft air
seal.
(3) Install 10 equally spaced screws into inner flange of aft air seal. Tighten screws
alternately, and evenly, until all are seated.
(4) Install remaining screws into inner flange of aft air seal. Finger-tighten screws.
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(5) Install one air cover baffle centered at 12:00 o'clock position onto outer flange of
aft air seal and secure using three screws. Finger-tighten screws.
(6) Install remaining 23 air cover baffles and secure using screws. Finger-tighten
screws.
(7) Check run-on torque of all aft air seal retaining screws. If run-on torque is less
than 3.5 lb in. (0.39 N·m), replace nut assembly (gang channel) per paragraph 13
and 14.
(8) Tighten all screws on inner and outer flanges of aft air seal to 70-80 lb in.
(8.0-9.0 N·m) of torque.
13. Nut Assembly (Gang Channel) Removal.
A. Drill out rivets using a 0.0625-inch (1.59 mm) drill.
B. Remove nut assembly (gang channel).
14. Nut Assembly (Gang Channel) Installation.
A. Install new nut assembly (gang channel) aligning nutplates with holes in part flange.
CAUTION
Do not use hammer and block to seat rivets. Part damage may result.
B. Install rivets so manufactured head sits flush in countersunk hole in part flange. Seat
rivets using rivet squeezer to secure nut assembly (gang channel).
C. Inspect rivets for proper installation. No looseness or cracks allowed.
22
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WORK PACKAGE
TECHNICAL PROCEDURES
HIGH PRESSURE TURBINE (HPT) MODULE
REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 44
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 43 ...... 6
44 Blank . . . . . . 6
Alphabetical Index
Subject Page
High Pressure Turbine (HPT) Module Installation ..................................................................... 23
High Pressure Turbine (HPT) Module Removal......................................................................... 4
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1. Introduction.
This work package contains instructions for removing and installing the high pressure turbine
(HPT) module.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Low Pressure Turbine (LPT) Module Replacement WP 2710 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture Assy, Lift - HPT Rotor Horizontal 1C9358G03
Holder, Shim - HPT Pressure Tube Adapter 1C9397G01
Stand - HPT Rotor Stage 2 Nozzle - Horiz 1C9417G01
Fixture, Install/Remove - HP Turbine Module 1C9608G02
Pilot, LP Mid Shaft - Aft 1C9610G01
Torque Adapter, Pressure Tube/Coupling 1C9626G01
Nut - HPT Rotor
Pusher Set, Races/Seals - HPTR Stage 1 2C14025G05
Fixture, Seat Check - No. 4B Bearing and Seal 2C14094G06
Fixture, Seat Check - HPT Rotor 2C14131G02
Stand, Shipping/Storage - HPT Module 2C14193G03
Fixture, Install/Remove - HPT Module 2C14199G10
Assembly
Fixture Assy, Lift - HPT Rotor Horizontal 2C14220G02
(Alternate to 1C9358G03)
Wrench Set, No. 5R Bearing Inner Race 2C14664G01
Nut
Sleeve, Retaining - No. 4B Bearing 2C14679P01
Stack-up
Puller, Races and Seals - HPT Rotor 2C14688G05
Stage 1
Fixture, Remove - HPT Rotor Aft Outer 2C14784G01
Air Seal
Fixture, Pull - HPT Rotor Aft Air Seals 2C14785G02
Torque Multiplier Sweeney Model 8112B
(or equivalent)
Torque Multiplier Sweeney Model 8200
(or equivalent)
Torque Multiplier Sweeney Model 8202A
(or equivalent
2 Change 6
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4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
Marking Pen Sharpie T.E.C.
(Black or Blue)
Penetrating Oil GE Spec A50TF54,
CL-A
Petrolatum Fed Spec VV-P-236
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK 108735, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Nut, Self-locking 9283M41P04 24
Shim 9219M19P05 1
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6. High Pressure Turbine (HPT) Module Removal.
A. Remove the low pressure turbine (LPT) module to gain access per WP 2710 00.
B. Disconnect and connect electrical leads and connecting tubes between HPT module
and gas turbine per SWP 1913 02.
NOTE
After a HPTR seal fracture event in which pieces of the seal have
separated/liberated, the HPTR stage 2 disk can be exposed to elevated
temperatures. HPTR seal separation/liberation is an abnormal condi-
tion that requires special inspection and disposition.
C. If engine has experienced a HPTR seal fracture with any pieces of the seal
separating/liberating, perform the following:
• document overall seal condition
• document amount of missing metal (% of seal separated/liberated)
• document total operating hours and cycles accumulated on seal since new
• photograph seal
• provide seal documentation and photographs to GE for review and identification
of special inspection and disposition required on the HPTR beyond manual
requirements.
D. Apply penetrating oil onto threads of nuts and bolts retaining aft air seals. Apply pen-
etrating oil onto threads of nuts and bolts retaining HPT to compressor rear frame
(CRF). Allow penetrating oil to soak for 20 minutes.
E. Remove aft air seals as follows:
(1) Using marking pen, matchmark aft air seals to stage 2 HPT rotor disk. Remove
nuts and bolts retaining aft air seals and pressure tube/coupling nut onto stage 2
HPT rotor disk. Discard nuts.
(2) Remove assembled aft air seals from stage 2 HPT rotor disk using pull fixture,
2C14785, as follows (figure 1):
1
(a) Loosen clamp knobs on pull fixture, 2C14785, and move slide clamps
inward.
(b) Connect an overhead hoist and lift sling through pull fixture, 2C14785,
holes.
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Figure 1. HPT Rotor Aft Air Seals Pull Fixture, 2C14785
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(c) Install pull fixture, 2C14785, over mid shaft so that rest pads are against stage 2 HPT
rotor disk. Move slide clamps outwards to engage aft air seal. Hand-tighten clamp
knobs to secure.
(d) Install guide tube.
(e) Take up slack on hoist to support pull fixture, 2C14785.
(f) Tighten jackscrews slowly and evenly to remove aft air seals.
WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they
can cause an injury or death.
(3) Separate aft air seal from aft outer air seal using fixture, 2C14784, as follows
(figure 2):
(a) Install assembled aft air seals onto base plate.
(b) Install adapter plate over aft air seal.
(c) Tighten jackscrew to separate aft air seal from aft outer air seal.
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2
Figure 2. HPT Rotor Aft Outer Air Seal Remove Fixture, 2C14784
F. Install rotor locking feature of removal fixture, 1C9608, as follows (figure 3):
NOTE
Inner support, 1C9608P10; clamp plate, 2C14199P96; clamp plug,
2C14199P97; locknut, 2C14199P98; and shoulder bolt,
2C14199P99, are maintained as an assembly.
(1) If installed, remove mid shaft pilot, 1C9610.
(2) Thread inner support, 1C9608P10, onto aft end of mid shaft until fully seated.
(3) Adjust clamp plug, 2C14199P97, forward so that clamp plate, 2C14199P96, rests against
inner support.
(4) Apply thread lubricant onto threads of center shaft, 1C9608P05.
(5) Install center shaft, 1C9608P05, so that male-threaded end engages threads on inside
diameter of compressor rotor aft shaft. Thread center shaft until seated against end of
compressor rotor aft shaft, then back off one-half turn.
3
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Figure 3. HPT Rotor Locking Feature from 1C9608
(6) Adjust clamp plug, 2C14199P97, aft so clamp plug is seated firmly against inside shoul-
der of center shaft, 1C9608P05. Lock into position using locknut, 2C14199P98. Tighten
clamp plug to 180 lb in. (20.3 N·m) of torque.
G. Remove pressure tube/coupling nut as follows (figure 4):
4
(1) Install antitorque tube, 1C9626P02, with leg, 1C9626P05, onto HPT rotor aft flange.
Rotate forward ring of tube to misalign lugs and slots. Install quick-release pin,
1C9626P12.
(2) Using clamp, 1C9626P06, and knob, 1C9626P08, secure leg, 1C9626P05, onto stage 2
HPT nozzle support flange. Hand-tighten knob.
(3) Install torque tube, 1C9626P03, into pressure tube/coupling nut. Align torque tube so
splines engage splines on pressure tube/coupling nut.
(4) Install torque multiplier, Sweeney Model 8112B, or equivalent, so multiplier splines
engage splines on torque tube, 1C9626P03.
8 Change 6
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Figure 4. HPT Rotor Pressure Tube/Coupling Nut Torque Adapter, 1C9626
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WARNING
Stand clear of engine when using torque multiplier. Torque in
excess of 20,000 lb ft (27,120 N·m) may be required to break cou-
pling nut loose. If parts should fail, they will do so with explosive
force and could cause serious injury.
NOTE
Pressure tube/coupling nut has right-hand threads.
(5) Actuate torque multiplier to loosen pressure tube/coupling nut.
(6) Remove pressure tube/coupling nut and shim (if installed). Remove torque mul-
tiplier and all components of torque adapter, 1C9626.
H. If same HPT rotor will be installed, matchmark stage 2 HPT disk rear face inner
diameter in line with X mark on aft surface of high pressure compressor (HPC) rotor
aft shaft using marking pen.
I. Measure from seating flange of stage 2 HPT rotor disk aft seal flange to aft surface of
HPC rotor aft shaft using seating check fixture, 2C14131. See figure 5. Record as
HSA (Before Disassembly) on HPT Worksheet. See figure 6.
1 .
Figure 5. Measure Seating Check Dimension HSA
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5
Figure 6. HPT Worksheet
Change 6 11
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J. Install HPT module removal fixture, 1C9608, as follows:
CAUTION
Ensure HPT module removal fixture, 1C9608, is used properly.
Failure to comply will cause tool and/or engine damage.
(1) Apply thread lubricant onto threads of bearing adapter shaft, 2C14199P102.
(2) Assemble lift adapter, 2C14199P53, lift fixture, 2C14199P22, and lifteye, 2C14199P36.
Attach to bearing adapter shaft, 2C14199P102.
(3) Thread center plate, 2C14199P103, onto extension shaft, 2C14199P104. Thread assem-
bly into center shaft, 1C9608P05. See figure 7.
(4) If not already attached, install frame extension, 1C9608P02, onto frame, 2C14199P123.
Figure 7. Bearing Adapter Shaft from Fixture, 2C14199
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(5) Install frame, 2C14199P123/1C9608P02, with support shaft, 2C14199P111, onto HPT
module as follows (figure 8):
(a) Position frame, 2C14199P123/1C9608P02, and support shaft, 2C14199P111, at aft
end of HPT module.
(b) Attach lift fixture, 1C9608P11, with lifteye, 2C14199P38, onto frame,
2C14199P123/1C9608P02, at 6:00 o’clock and 12:00 o’clock positions. Secure with
thumbscrews.
(c) Attach horizontal lift fixture, 1C9358 or 2C14220, onto frame,
2C14199P123/1C9608P02.
(d) Attach overhead hoists onto lift fixture, 1C9608P11, and horizontal lift fixture,
1C9358 or 2C14220.
WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they
can cause an injury or death.
(e) Lift frame, 2C14199P123/1C9608P02, and support shaft, 2C14199P111 to align
with aft end of HPT module.
(f) Move tooling into HPT module. Support shaft, 2C14199P111, shall fit into rabbet of
stage 2 disk aft flange. Frame, 2C14199P123, shall fit into rabbet of stage 2 HPT
nozzle support aft flange.
(g) Using 12 bolts, 2C14199P43, and nut plates, 2C14199P27, secure support shaft,
2C14199P111, onto stage 2 disk aft flange. Tighten bolts, 2C14199P43, to
70-110 lb in. (7.9-12.4 N·m) of torque.
(h) Using 30 bolts, 2C14199P43, six nut plates, 2C14199P34, and six nut plates,
2C14199P35, secure frame, 2C14199P123/1C9608P02, onto stage 2 HPT nozzle
support aft flange. Tighten bolts, 2C14199P43, to 70-110 lb in. (7.9-12.4 N·m) of
torque.
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Figure 8. HPT Module Antirotation Tools from 2C14199/1C9608
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(6) Install guide tube, 1C9608P04, over center shaft, 1C9608P05, so that guide tube seats
against compressor rotor aft shaft. See figure 9.
(7) Apply light coat of petrolatum onto No. 5R bearing rollers. Push rollers outward in outer
race using finger pressure.
(8) Install 24 guide pins, 2C14199P33, in sets of three, through stage 2 HPT nozzle support
forward flange into blocks, 2C14199P26. Do not install pins, 2C14199P33, at 6:00
o’clock and 12:00 o’clock positions. See figure 8.
(9) Install pusher shaft, 1C9608P03, as follows (figure 9):
(a) Ensure that the HPTR shaft inner diameter and seating shoulder are clean and free of
foreign material or high metal.
(b) Install lift fixture, 2C14199P22, with lifteye, 2C14199P36, into aft end of pusher
shaft, 1C9608P03.
WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they can
cause an injury or death.
(c) Lift pusher shaft, 1C9608P03, to align with HPT module.
(d) Insert pusher shaft, 1C9608P03, into aft end of HPT module until pusher shaft,
1C9608P03, contacts bearing adapter shaft, 2C14199P102.
(e) Rotate retainer nut, 2C14199P70, clockwise (CW) so that slots in retainer nut align
with slots in support shaft, 2C14199P111, and lugs of pusher shaft, 1C9608P03.
(f) Rotate retainer nut, 2C14199P70, CW to lock.
(g) Rotate bearing adapter shaft, 2C14199P102, by hand, while holding pusher shaft,
1C9608P03, stationary to move pusher shaft forward until pusher shaft threads
engage bearing adapter shaft threads. Continue hand-tightening until pusher shaft,
1C9608P03, is fully threaded onto bearing adapter shaft.
6
(10) Remove lift fixture, 2C14199P22, and lifteye, 2C14199P36.
(11) Position spacer foot, 2C14199P65, aft of HPT. Secure spacer foot, 2C14199P65, onto
foot bracket, 2C14199P66, using quick-release pins, 2C14199P74.
(12) Install torque multiplier, Sweeney Model 8200, onto splines of pusher shaft, 1C9608P03.
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Figure 9. HPT Module Removal Tools from Fixture, 2C14199/1C9608
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(13) Install antirotation strap, 2C14199P25, over square shank of bearing adapter shaft,
2C14199P102. Using four hand knobs, 2C14199P23, secure antirotation strap,
2C14199P25, to frame, 2C14199P123/1C9608P02.
(14) Loosen clamp on lift fixture enough to permit support shaft, 2C14199P111, to rotate and
still support module and tooling.
K. Remove HPT module as follows:
WARNING
Serious injury can occur when applying pneumatic pressure. Eye
protection is required. Relieve pressure before disconnecting lines
and fittings.
CAUTION
• The high pressure compressor (HPC) and low pressure compres-
sor (LPC) rotors will rotate during HPT module removal. Ensure
LPC inlet is clear of foreign objects and rotors are free to rotate.
• Do not exceed 900 lb ft (1220 N·m) of output torque.
NOTE
• The HPT rotor and pusher shaft, 1C9608P03, will rotate counter-
clockwise (CCW) and move aft during removal. The frame,
2C14199P123/1C9608P02, and torque multiplier will not rotate,
but will move aft.
• The module removal operation may be stopped and started as nec-
essary without causing bearing damage. Tooling shall remain in
place at all times.
(1) Apply CCW input torque to torque multiplier. Pneumatic torque multiplier, Sweeney
Model 8202A, (in direct drive) may be used in combination with torque multiplier,
Sweeney Model 8200, at a pressure of 90 psi (621 kPa) to reduce installation time.
(2) Apply torque until the CRF flange is outside of the second scribe line on guide pins,
2C14199P33. See figure 8. This will ensure that the HPT module has moved aft far
enough.
(3) Install spacer foot, 2C14199P65, (figure 9) between CRF and HPT stator support. Secure
spacer foot to foot bracket, 2C14199P66, using quick-release pins, 2C14199P74.
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(4) Reverse rotation on torque multipliers a minimum of one full turn to relieve internal ten-
sion on tooling.
(5) Turn retaining nut, 2C14199P70, CCW to unlock pusher shaft, 1C9608P03, lugs.
(6) Reverse Sweeney torque multiplier two or three complete turns to release load on threads
between bearing adapter shaft, 2C14199P102, and pusher shaft, 1C9608P03.
(7) Remove antirotation strap, 2C14199P25, and Sweeney torque multiplier.
WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they
can cause an injury or death.
(8) Remove pusher shaft, 1C9608P03, as follows:
(a) Rotate bearing adapter shaft, 2C14199P102, in CW direction, aft looking forward.
(b) Attach lift fixture, 2C14199P22, and lifteye, 2C14199P36, to aft end of pusher shaft,
1C9608P03.
(c) Remove pusher shaft, 1C9608P03, from aft end of HPT module.
(9) Remove guide pins, 2C14199P33, and blocks, 2C14199P26. See figure 8.
(10) Install eight bolts, 2C14199P43, evenly spaced with bolt heads forward. Tighten bolts,
2C14199P43, to 210-230 lb in. (23.7-26.0 N·m) of torque.
(11) Tighten hand knob, 1C9358P31 or 2C14220P18, of HPT horizontal lift fixture, 1C9358
or 2C14220.
(12) Ensure that lift fixture, 1C9608P11, and horizontal lift fixture, 1C9358 or 2C14220, are
still attached to frame, 2C14199P123/1C9608P02, and overhead hoist for support while
moving HPT module. Tighten clamp on horizontal lift fixture, 1C9358 or 2C14220, if
necessary.
(13) Remove HPT module by pulling tooling aft.
(14) Install retaining sleeve, 2C14679P01, to secure No. 4B bearing inner race. Ensure that
retaining sleeve is firmly installed.
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NOTE
If same HPT rotor will be installed, proceed to step N.
L. Install HPT module into support stand, 1C9417, as follows (figure 10):
(1) Lower HPT module into support stand, 1C9417, so the frame, 2C14199P123,
sits on the four vertical supports.
(2) Secure HPT module into support stand, 1C9417, by positioning four swing
clamps against frame.
CAUTION
The No. 5R bearing is a matched assembly. Ensure matched
bearing components are kept together as sets by serial numbers.
Mixing of serviceable matched bearing components may result
in engine damage.
M. Remove No. 5R bearing inner race as follows:
(1) Pull heat shield from HPT forward shaft using puller, 2C14688.
(2) Install wrench, 2C14664, onto No. 5R bearing spanner nut. Attach torque multi-
plier, Sweeney Model 8200, or equivalent, to wrench.
(3) Activate torque multiplier to remove No. 5R bearing spanner nut.
(4) Using puller, 2C14688, remove No. 5R bearing inner race.
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Figure 10. HPT Rotor Shaft Seals and Bearing Races Install/Remove Stand, 1C9417
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N. Install HPT module into shipping/storage stand, 2C14193, as follows (figure 11):
(1) Attach vertical lift fixture, 1C9608P11, with lifteye, 2C14199P38, onto frame at
6:00 and 12:00 o'clock positions. Secure using thumbscrews.
CAUTION
Do not loosen swing clamps unless weight of HPT module is
supported by horizontal lift fixture, 1C9358. Failure to comply
may cause module damage.
(2) Ensure that weight of HPT module is supported by horizontal lift fixture, 1C9358
or 2C14220. Disconnect four swing clamps on support stand, 1C9417.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or
fall, they can cause an injury or death.
(3) Lift module from support stand.
(4) Connect a second hoist onto vertical lift fixture. Turn HPT module so forward end
is down. Remove horizontal lift fixture, 1C9358 or 2C14220.
(5) Lower HPT module into shipping/storage stand, 2C14193. Secure case to leveling
screws using washers and nuts. Tighten nuts to 55-70 lb in. (6.2-7.9 N·m) of
torque.
(6) Install plug into aft bore of stage 2 HPT rotor disk. Secure plug using rod.
Safety-wire plug to rod.
(7) Remove HPT module removal fixture, 2C14199.
7
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Figure 11. HPT Module Shipping/Storage Stand, 2C14193
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7. High Pressure Turbine (HPT) Module Installation.
A. Remove retaining sleeve, 2C14679P01, from gas turbine core.
NOTE
All dimensions in this WP shall be measured at eight locations. The
average of these measurements shall determine the dimension.
B. Compute seating dimension HSA as follows:
(1) Measure from aft face of forward HPT rotor shaft inner seating shoulder onto aft
face of stage 2 HPT disk aft mounting flange. Record as dimension J on HPT
Worksheet. See figure 12 and figure 6. For reference, dimension J should be
15.783-15.824 inches (400.89-401.92 mm). Remeasure dimension J if not within
range.
(2) Measure from aft face of No. 4B bearing inner race onto aft face of compressor
rotor aft shaft using seat check fixture, 2C14094. Record as dimension CCM on
HPT Worksheet. See figure 13 and figure 6. If dimension CCM is not within
8.921-8.948 inches (226.60-227.27 mm), No. 4B bearing inner race has backed
out, remeasure to validate.
8
Figure 12. Dimension J Measurement
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9
Figure 13. Dimension CCM Measurement
CAUTION
When using 6-inch parallel bar on aft face of pressure tube/coupling
nut shoulder, assure parallel bar is not seated on radius.
(3) Measure from forward face of HPT rotor shaft onto aft face of pressure tube/cou-
pling nut sealing shoulder. Record as dimension EHS on HPT Worksheet. See
figure 14 and figure 6. For reference, dimension EHS should be 7.137-7.147
inches (181.28-181.53 mm). Remeasure if dimension EHS is not with in the range.
10
(4) Compute seating dimension HSA using the following equation and record as HSA
(Calculated) on HPT Worksheet. See figure 6.
HSA = EHS + J − CCΜ
11
C. Determine if HPT rotor aft seal shim is required as follows:
(1) Measure from forward most point of pressure tube/coupling nut to forward side
of pressure tube/coupling nut mounting flange. Record as dimension V on HPT
Worksheet. See figure 15 and figure 6.
(2) Subtract dimension J from dimension V. See figure 6. If difference is greater than
0.027 inch (0.69 mm), one shim is required. If difference is less than 0.027 inch
(0.69 mm), no shim is required.
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Figure 14. Dimension EHS Measurement
Figure 15. Dimension V Measurement
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D. Install rotor locking feature of removal fixture, 1C9608, as follows (figure 16):
NOTE
Inner support, 1C9608P10; clamp plate, 2C14199P96; clamp plug, 2C14199P97; lock-
nut, 2C14199P98; and shoulder bolt, 2C14199P99, are maintained as an assembly.
(1) If installed, remove mid shaft pilot, 1C9610.
(2) Thread inner support, 1C9608P10, onto aft end of mid shaft until fully seated.
(3) Adjust clamp plug, 2C14199P97, forward so that clamp plate, 2C14199P96, rests against
inner support.
(4) Apply thread lubricant onto threads of center shaft, 1C9608P05.
(5) Install center shaft, 1C9608P05, so male-threaded end engages threads on inside diameter
of compressor rotor aft shaft. Thread center shaft until seated against end of compressor
rotor aft shaft, then back off one-half turn.
(6) Adjust clamp plug, 2C14199P97, aft so that clamp plate, 2C14199P96, is seated firmly
against inside shoulder of center shaft, 2C14199P29. Lock into position with locknut,
2C14199P98. Tighten clamp plug to 180 lb in. (20.3 N·m) of torque.
12
Figure 16. HPT Module Centering Tools from 2C14199
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Figure 17. Bearing Adapter Shaft from 1C9608
E. Install HPT module installation fixture, 2C14199, as follows (figure 17):
CAUTION
Ensure HPT module installation fixture, 1C9608, is used properly. Failure
to comply will cause tool and/or engine damage.
(1) Apply thread lubricant onto threads of bearing adapter shaft, 2C14199P102.
(2) Assemble lift adapter, 2C14199P53, lift fixture, 2C14199P22, and lifteye, 2C14199P36.
Attach to bearing adapter shaft, 2C14199P102.
(3) Thread center plate, 2C14199P103, into extension shaft, 2C14199P104. Thread assem-
bly into center shaft, 1C9608P05.
(4) If installed, remove plug, 2C14193P04, from HPT rotor.
(5) Remove nuts and washers that secure HPT module onto shipping/storage module.
(6) Install frame, 2C14199P123/1C9608P02, with support shaft, 2C14199P111, onto HPT
module as follows:
(a) If not already attached, install frame extension, 1C9608P02, onto frame
2C14199P123.
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(b) Position frame, 2C14199P123/1C9608P02, so three spacer feet, 2C14199P65 face
up.
(c) Attach vertical lift fixture, 1C9608P11, with lifteye, 2C14199P38, onto frame,
2C14199P123/1C9608P02, at 6:00 o’clock and 12:00 o'clock positions. Secure with
hand knob, 2C14199P23.
WARNING
Always use approved equipment and procedures to lift parts. Stay out
from below loads. If the parts accidentally move or fall, they can cause
an injury or death.
(d) Attach hoist to lifteye, 2C14199P38. Lift frame, 2C14199P87/1C9608P02, and sup-
port shaft, 2C14199P111, over HPT rotor.
(e) Lower tooling onto HPT module. Support shaft, 2C14199P111, shall fit into rabbet
of stage 2 HPT disk aft flange. Frame shall fit into rabbet of stage 2 HPT nozzle sup-
port aft flange. See figure 18.
(f) Install spacer foot, 2C14199P65, onto forward flange of HPT stator support.
Using quick-release pins, 2C14199P74, secure spacer foot onto foot bracket,
2C14199P66. See figure 19.
(g) Secure support shaft, 2C14199P111, onto stage 2 HPT rotor disk aft rabbet using 12
bolts, 2C14199P43, and nut plate 2C14199P27. Tighten bolts to 70-110 lb in.
(7.9-12.4 N·m) of torque. See figure 18.
(h) Secure frame onto stage 2 HPT nozzle support aft flange using 30 bolts,
2C14199P43, six nut plates, 2C14199P34, and six nut plates, 2C14199P35. Tighten
bolts to 70-110 lb in. (7.9-12.4 N·m) of torque.
(7) Install pusher shaft, 1C9608P03, as follows (figure 19):
(a) Ensure HPT rotor shaft inner diameter and seating shoulder are clean and free of for-
eign material or high metal.
(b) Remove vertical lift fixture, 1C9608P11.
(c) Install lift fixture, 2C14199P22, with lifteye, 2C14199P36, into aft end of pusher
shaft, 1C9608P03. Raise pusher shaft over HPT module.
(d) Rotate retainer nut, 2C14199P70, counterclockwise so that slots in retainer nut align
with slots in support shaft, 2C14199P111.
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Figure 18. HPT Support Shaft from 2C14199
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Figure 19. Pusher Tools from 2C14199/1C9608
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(e) Insert pusher shaft, 1C9608P03, into aft end of HPT module. Align lugs of pusher
shaft with slots of support shaft, 2C14199P111, and retainer nut, 2C14199P70.
(f) Rotate retainer nut, 2C14199P70, CW.
(g) Remove lift fixture, 2C14199P22, and lifteye, 2C14199P36.
(h) Attach vertical lift fixture, 1C9608P11.
NOTE
If same HPT rotor is being installed, disregard steps F. and G.
F. Install HPT module into support stand, 1C9417, as follows (figure 20):
13
(1) Attach horizontal lift fixture, 1C9358 or 2C14220, onto frame,
2C14199P123/1C9608P02.
(2) Connect overhead hoist to vertical lift fixture, 1C9608P11.
WARNING
Always use approved equipment and procedures to lift parts. Stay out
from below loads. If the parts accidentally move or fall, they can
cause an injury or death.
(3) Lift HPT module from shipping/storage stand, 2C14193.
(4) Connect second hoist onto shackle on horizontal lift fixture, 1C9358 or 2C14220.
(5) Turn HPT module to horizontal position.
(6) Lower HPT module into support stand, 1C9417, so the frame,
2C14199P123/1C9608P02, sits on the four vertical supports.
(7) Secure HPT module into support stand, 1C9417, by positioning four swing clamps
against frame, 2C14199P123/1C9608P02.
G. Install No. 5R bearing inner race as follows:
WARNING
Use thermal gloves when you move or touch hot parts. Hot parts
can cause injury.
(1) If required, heat rotating air seal in oven for 30 minutes at 350°F (176.7°C) and install
onto HPT forward shaft.
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Figure 20. HPT Rotor Shaft Seals and Bearing Races Install/Remove Stand, 1C9417
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(2) Heat No. 5R bearing inner race in oven for 30 minutes at 350°F (176.7°C).
(3) Install bearing inner race onto HPT forward shaft using pusher, 2C14025P08. Do
not remove pusher until temperature of inner race has normalized.
(4) Ensure bearing inner race is seated properly by attempting to insert a 0.002-inch
(0.05 mm) thick shim between inner race and 5R air/oil seal. Shim shall not fit
anywhere between parts except at puller relief grooves.
(5) Install No. 5R bearing spanner nut as follows:
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory tract.
Skin and eye protection is required. Avoid repeated or prolonged
contact. Use in a well-ventilated area.
(a) Clean threads of HPT forward shaft and spanner nut using isopropyl alcohol.
(b) Measure spanner nut minor thread diameter. See figure 21. Take measurement
at three axial locations on threads. The average of these three measurements
shall not exceed 7.684 in. (195.17 mm). Replace spanner nut if this require-
ment is not met.
14
(c) Apply a coat of thread lubricant onto threads of spanner nut.
(d) Install spanner nut over HPT rotor shaft engaging threads just forward of
No. 5R bearing inner race. Chamfer faces forward.
(e) Tighten spanner nut until threads extend through nut locking insert. Use
wrench, 2C14664; torque multiplier, Sweeney Model 8200, or equivalent; and
a torque wrench.
(f) Measure torque required to start spanner nut moving (with nut not bottomed
out). A minimum of 25 lb ft (34 N·m) of torque shall be present. Replace
spanner nut if this requirement is not met.
(g) Tighten spanner nut to 2000-2300 lb ft (2712-3118 N·m) of torque.
(h) Wipe excess thread lubricant from spanner nut and inner race.
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WP 2610 00
Figure 21. No. 5R Bearing Spanner Nut Minor Thread Diameter
(6) Install heat shield as follows:
(a) Place the heat shield into oven for 20 minutes at maximum temperature 400°F
(204.4°C).
WARNING
Use thermal gloves when you move or touch hot parts. Hot parts
can cause injury.
(b) Remove heat shield from oven and install onto stage 1 HPT disk/shaft as follows:
1 Align Z mark on heat shield with Z mark on shaft.
2 Put two tabs on ID of heat shield into two notches on shaft.
3 Seat heat shield by hand.
34 Change 6
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NOTE
If removal of heat shield is necessary after it has been installed,
use HPT rotor stage 1 races and seals puller, 2C14688.
4 After heat shield and shaft have reached the same temperature, take a
drop check from the forward end of shaft to forward end of heat shield.
Drop check dimension must be 0.240-0.350 inch (6.10-8.89 mm).
H. Install HPT module as follows:
CAUTION
Ensure HPT rotor is free to rotate, or damage to rotor may occur.
(1) Rotate HPC rotor until X mark is at 6:00 o'clock position.
(2) Transfer X mark from forward surface of stage 1 HPT disk shaft to stage 2 HPT
disk rear face inner diameter.
NOTE
Ensure X marks on HPC and HPT are at same circumferential
location.
(3) Rotate HPT rotor until X mark is at 6:00 o'clock position.
(4) Install guide tube, 1C9608P04, into engine over center shaft, 1C9608P05, until
tube seats against compressor rotor aft shaft. See figure 19.
(5) Apply light coat of petrolatum onto No. 5R bearing rollers. Push rollers outward
in outer race using finger pressure.
(6) Install 24 guide pins 2C14199P33, in sets of three, through stage 2 nozzle support
forward flange into blocks, 2C14199P26. Do not install pins at 6:00 o’clock and
12:00 o'clock positions.
(7) Remove HPT module support stand, 1C9417, as follows:
(a) Attach horizontal lift fixture, 1C9358 or 2C14220, onto frame,
2C14199123/1C9608P02.
(b) Connect overhead hoist onto horizontal lift fixture, 1C9358 or 2C14220.
(c) Connect second hoist onto shackle on horizontal lift fixture, 1C9358 or
2C14220.
(d) Release four swing clamps.
Change 6 35
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WP 2610 00
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the part accidentally move or fall,
they can cause injury or death.
(e) Slowly lift HPT module from support stand, 1C9417.
CAUTION
HPT module shall be slid into core engine only until CRF aft
flange is between scribed lines on guide pins. Failure to comply
may cause bearing damage.
(8) Slide HPT module into core engine until guide tube, 1C9608P04, just contacts
bearing adapter shaft, 2C14199P102, and guide pins, 2C14199P33, pass through
CRF aft flange. Do not slide HPT module beyond the point where CRF aft flange
is between scribed lines on guide pins.
(9) Position spacer feet, 2C14199P65, aft. Secure spacer feet in foot bracket,
2C14133P66, with quick-release pins, 2C14199P74. See figure 19.
(10) Hold pusher shaft, 1C9608P03, stationary while rotating bearing adapter shaft,
2C14199P102, to move pusher shaft forward until threads engage bearing adapter
shaft threads. Continue hand-threading until guide pins, 2C14199P33, pass
through CRF flange.
(11) Install torque multiplier, Sweeney Model 8200, or equivalent, onto pusher splines.
Secure torque multiplier to frame using two knurled head screws, 2C14199P41.
(12) Install antirotation strap, 2C14199P25, over square shank of bearing adapter shaft,
2C14199P102. Secure antirotation strap to frame with handknobs, 2C14199P23.
(13) Loosen clamp on lift fixture enough to permit support shaft, 2C14199P111, to
rotate and still support module and tooling.
36 Change 6
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WP 2610 00
WARNING
Serious injury can occur when applying pneumatic pressure. Eye pro-
tection is required. Relieve pressure before disconnecting lines and fit-
tings.
CAUTION
• The HPC and LPC rotors will rotate during HPT module installation.
Ensure LPC inlet is clear of foreign objects and rotors are free to
rotate.
• Do not exceed 900 lb ft (1220 N·m) of output torque.
NOTE
• The HPT rotor and tooling will rotate clockwise and move forward
during installation. The frame and torque multipliers will not rotate,
but will move forward.
• The installation operation may be stopped and started as necessary
without causing bearing damage. Tooling shall remain in place at all
times.
(14) Apply input torque of 80 lb ft (108 N·m) to torque multiplier. Pneumatic torque multi-
plier, Sweeney Model 8202A, or equivalent, (in direct drive) may be used in combination
with torque multiplier, Sweeney Model 8200, or equivalent, at a pressure of 90 psi
(621 kPa) to reduce installation time.
I. Remove tooling as follows:
(1) Rotate retainer nut, 2C14199P70, counterclockwise to unlock pusher shaft lugs. Reverse
torque multiplier two or three revolutions to release load on threads between HPT rotor
shaft and pusher shaft.
(2) Remove antirotation strap, 2C14199P25, and torque multiplier.
(3) Remove pusher shaft, 1C9608P03, as follows:
(a) Rotate bearing adapter shaft, 2C14199P102, (figure 17) clockwise to back out
pusher shaft, 1C9608P03.
(b) Install lift fixture, 2C14199P22, with lifteye, 2C14199P36, into aft end of pusher
shaft, 1C9608P03. Remove pusher shaft from HPT module.
(4) Remove guide pins, 2C14199P33, and blocks, 2C14199P26. See (figure 8).
Change 6 37
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(5) Install eight flange bolts, 2C14199P43, as evenly spaced as possible. Bolt heads should
face forward. Tighten bolts to 210-230 lb in. (23.7-26.0 N·m) of torque.
(6) Tighten clamp onto horizontal lift fixture, 1C9358 or 2C14220.
(7) Remove bolts, 2C14199P43, and nut plates, 2C14199P34 and 2C14199P35 from HPT
stator support aft flange. Remove bolts, 2C14199P43, and nut plates, 2C14199P27, from
stage 2 disk aft flange.
(8) Remove frame, 2C14199P123/1C9608P02, and support shaft, 2C14199P111.
(9) Remove guide tube, 1C9608P04.
J. Perform HPT rotor seating check as follows:
(1) Inspect pressure tube/coupling nut threads and forward face for dirt, burrs, or high metal.
No dirt, burrs, or high metal allowed.
CAUTION
Do not allow alignment pins to extend through the aft side of the shim.
Failure to comply will cause damage to pressure tube/coupling nut.
(2) If required, install HPT rotor shim, PN 9219M19P05, onto aft flange of stage 2 disk.
Install shim holder, 1C9397, to keep shim holes aligned with flange holes when pressure
tube/coupling nut is tightened.
NOTE
To facilitate pressure tube/coupling nut installation, loosen center shaft,
1C9608P05, two complete turns. Ensure that rotor locking fixture of
removal fixture, 1C9608, is installed prior to performing next step.
(3) Thread pressure tube/coupling nut onto HPC aft shaft. Hand-tighten pressure
tube/coupling nut.
(4) Install antitorque tube, 1C9626P02, onto stage 2 HPT rotor seal flange. Rotate forward
ring on tube to misalign lugs and slots. Install quick-release pin.
(5) Using clamps, 1C9626P06, and knob, 1C9626P08, secure leg, 1C9626P05, onto stage 2
HPT nozzle support flange. Hand-tighten knob.
(6) Install torque tube, 1C9626P03, into inside diameter of pressure tube/coupling nut so
that splines engage.
(7) Install torque multiplier, Sweeney Model 8112B, or equivalent, onto torque tube,
1C9626P03.
38 Change 6
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CAUTION
Do not exceed maximum torque.
(8) Tighten pressure tube/coupling nut to 9,500 lb ft (12,880 N·m) of torque.
(9) Break torque on pressure tube/coupling nut. Remove pressure tube/coupling nut,
shim and all tooling except rotor locking tools.
(10) Measure from seating flange of stage 2 HPT rotor disk aft seal flange to aft surface
of HPC rotor aft shaft using seating check fixture, 2C14131. See figure 22. Record
measurement on HPT Worksheet as HSA (After Assembly). See figure 6. This
dimension shall be within 0.002 inch (0.05 mm) of HSA (Calculated) determined
in step B.(4). Repeat steps J.(1) through (10) if this requirement is not met.
15
K. Install pressure tube/coupling nut as follows:
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory tract.
Skin and eye protection is required. Avoid repeated or prolonged
contact. Use in a well-ventilated area.
(1) Using isopropyl alcohol, clean threads of pressure tube/coupling nut.
(2) Measure pressure tube/coupling nut minor thread diameter. See figure 23. Take
measurement at three axial locations on threads. The average of these three mea-
surements shall not exceed 6.388 in. (162.26 mm). Replace pressure tube/coupling
nut if this requirement is not met.
(3) Inspect pressure tube/coupling nut threads and forward face for burrs or high
metal. Remove burrs or high metal.
16
(4) Apply coat of thread lubricant onto threads, forward face, and flange forward face
of pressure tube/coupling nut.
CAUTION
Do not allow alignment pins to extend through the aft side of the
shim. Failure to comply will cause damage to pressure tube/cou-
pling nut.
(5) If required, install HPT rotor aft shim, PN 9219M19P05, onto seal flange of stage
2 HPT rotor disk. Install alignment pins into shim holder, 1C9397, to keep shim
holes aligned with flange holes when pressure tube/coupling nut is tightened.
Change 6 39
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WP 2610 00
Figure 22. HPT Rotor Seating Check Using Fixture, 2C14131
40 Change 6
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Figure 23. Pressure Tube/Coupling Nut Minor Thread Diameter
NOTE
Ensure that rotor locking fixture of removal fixture, 1C9608, is
installed prior to performing next step.
(6) Thread pressure tube/coupling nut onto HPC aft shaft. Hand-tighten pressure
tube/coupling nut.
(7) Install antitorque tube, 1C9626P02, onto HPT stage 2 rotor flange. Rotate forward
ring on tube to misalign lugs and slot. Install quick-release pin.
(8) Using clamp, 1C9626P06, and knob, 1C9626P08, secure leg, 1C9626P05, onto
stage 2 HPT nozzle support flange. Hand-tighten knob.
(9) Install torque tube, 1C9626P03, into inside diameter of pressure tube/coupling nut
so that splines engage.
(10) Install torque multiplier, Sweeney Model 8112B, or equivalent, onto torque tube,
1C9626P03.
(11) Tighten coupling nut to 1,000 lb ft (1,356 N·m) of torque.
(12) Using marking pen, mark zero point on torque multiplier.
Change 6 41
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CAUTION
Do not exceed maximum torque of 13,100 lb ft (17,761 N·m). Failure
to comply will cause damage to pressure tube/coupling nut.
(13) Continue to tighten pressure tube/coupling nut a minimum of 76 degrees beyond
zero point to minimum torque of 9,500 lb ft (12,880 N·m). Record angle and
torque.
(14) If maximum torque of 13,100 lb ft (17,761 N·m) is reached, remove pressure
tube/coupling nut and perform the following:
(a) Check torque multiplier for excessive drag.
(b) Inspect pressure tube/coupling nut threads and mating faces for dirt, burrs,
galling, or high metal. Clean and deburr threads and mating faces, if neces-
sary.
(c) Inspect outer diameter seal teeth for evidence of contact with HPT rotor shaft
inner diameter. If seal teeth have contacted HPT rotor shaft inner diameter,
replace pressure tube/coupling nut. Remove high metal from HPT rotor shaft
inner diameter.
(d) Inspect HPT rotor seating shoulder for dirt or metal pickup. Clean and deburr
HPT rotor seating shoulder, if necessary.
(e) Replace pressure tube/coupling nut if reason for excessive torque cannot be
determined.
CAUTION
Do not exceed a maximum of 84 degrees beyond zero point or a
maximum torque value of 13,800 lb ft (18,710 N·m).
(15) Continue tightening to align stage 2 HPT disk and pressure tube/coupling nut aft
flange boltholes to minimum torque of 9,500 lb ft (12,880 N·m). Record final
angle and torque.
(16) Remove all tooling.
(17) Inspect pressure tube/coupling nut inner diameter for displaced or damaged
damper sleeve. Replace pressure tube/coupling nut if damage is present.
42 Change 6
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L. Install aft air seals as follows:
(1) Apply thread lubricant onto threads and washer faces of bolts and new nuts,
PN 9283M41P04.
(2) Using bolts and self-locking nuts, 9283M41P04, secure aft air seals and pressure
tube/coupling nut to stage 2 HPT rotor disk. Tighten nuts to 220-240 lb in.
(24.9-27.1 N·m) of torque.
M. Install flange retaining hardware as follows:
(1) Apply thread lubricant onto threads and seating faces of flange retaining bolts.
(2) Install brackets at locations marked at disassembly. Using bolts and nuts, secure
brackets onto flange. Boltheads face forward. Tighten nuts to 210-230 lb in.
(23.7-26.0 N·m) of torque.
(3) Install remaining bolts, spacers, and nuts. Boltheads face forward, and spacers
mate directly with boltheads. Tighten nuts to 210-230 lb in. (23.7-26.0 N·m) of
torque.
Change 6 43/(44 Blank)
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WP 2611 00
2WP 2611 00
WORK PACKAGE
TECHNICAL PROCEDURES
STAGE 2 HIGH PRESSURE TURBINE (HPT) NOZZLE
(ON ENGINE) REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1-9 ...... 6
10 Blank . . . . . . 6
Alphabetical Index
Subject Page
Stage 2 HPT Nozzle Installation ................................................................................................. 5
Stage 2 HPT Nozzle Removal..................................................................................................... 3
Change 6 1
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WP 2611 00
1. Introduction.
A. This work package contains instructions for replacing the stage 2 high pressure turbine (HPT)
nozzle when HPT module is installed on engine.
B. Remove low pressure turbine (LPT) module to gain access per WP 2710 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Stage 2 High Pressure Turbine (HPT) Rotor Blades Replace- WP 2614 00
ment
Low Pressure Turbine (LPT) Module Replacement WP 2710 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture Assy, Lift - HPT Rotor Horizontal 1C9358G02 (ALT)
Fixture Assy, Lift - HPT Rotor Horizontal 1C9358G03
Adapter, Lift - HPT Nozzle, Stage 2 2C14703G01
4. Consumable Material.
Nomenclature Specification
Adhesive Scotch Grip 77
Dry Ice Fed Spec BB-C-104
Marking Pen Sharpie T.E.C. (Black
or Blue)
Masking Tape Local Purchase
Penetrating Oil GE Spec A50TF54,
CL-A
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Nut, Self-Locking 9985M32P06 74
Seal, Ring 9331M55P01 1
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6. Stage 2 HPT Nozzle Removal.
A. Remove stage 2 HPT rotor blades as follows (figure 1):
1
CAUTION
The procedures in this work package for removing and installing stage
2 HPT rotor blades are to facilitate other maintenance only. If stage 2
HPT rotor blades require replacement, refer to WP 2614 00.
(1) Apply penetrating oil onto threads of nuts that secure stage 2 blade retainer onto
stage 2 disk. Allow penetrating oil to soak for 20 minutes.
(2) Using marking pen, matchmark stage 2 blade retainer to stage 2 disk.
(3) Remove and discard nuts that secure stage 2 blade retainer. If any stud is broken,
or if any nut must be cut off, replace HPT module.
WARNING
Dry ice, BB-C-104: Do not let this material touch you. Low-tem-
perature skin damage. Can decrease available air. Asphyxiant.
Personal protective equipment required, especially insulated
gloves and eye protection when handling material. Use in a well-
ventilated area.
(4) Using dry ice, chill stage 2 blade retainer.
WARNING
Use thermal gloves when you move or touch hot or cold parts.
Hot or cold parts can cause injury.
CAUTION
Protect stage 2 disk from tool damage when prying stage 2 blade
retainer. Ensure prying tool has corner radii to prevent damage to
stage 2 blade retainer.
(5) Remove stage 2 blade retainer. Remove and discard ring seal.
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WP 2611 00
Figure 1. HPT Module
4 Change 6
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CAUTION
Ensure blade damper assemblies are matchmarked accurately.
Incorrect placement at installation will cause rotor imbalance.
(6) Using a marking pen, matchmark stage 2 blades to stage 2 disk. Begin with blade
in dovetail slot marked 1-1 and number all stage 2 blades consecutively in
clockwise direction. Mark number 1 through number 5 dovetail slots. Mark blade
damper assemblies, starting with number 1 at clockwise side of number 1 blade.
(7) Remove stage 2 blades and damper assemblies.
B. Remove stage 2 HPT nozzle as follows (figure 2):
2
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
(1) Using lift adapter assembly, 1C9358, and 1-ton (907 kg) overhead hoist, position
lift adapter, 2C14703, onto stage 2 HPT nozzle aft flange.
(2) Using three screws and nuts, secure lift adapter, 2C14703, onto stage 2 HPT
nozzle aft flange. Tighten nuts to 40-60 lb in. (4.5-6.8 N·m) of torque.
(3) Using masking tape and marking pen, matchmark brackets to compressor rear
frame (CRF) aft flange.
(4) Remove nuts, bolts, spacers, and brackets that secure stage 2 nozzle support
forward flange onto CRF aft flange. Do not remove four screws and nuts that
secure HPT hanger support.
(5) Carefully slide stage 2 HPT nozzle aft from HPT rotor assembly.
7. Stage 2 HPT Nozzle Installation.
CAUTION
Ensure stage 2 HPT nozzle part number is correct per IPB,
GEK 105060, before installation, or damage to engine could result.
A. Install stage 2 HPT nozzle as follows (figure 2):
(1) Using lift adapter assembly, 1C9358, and overhead hoist, position lift adapter,
2C14703, onto stage 2 HPT nozzle aft flange.
Change 6 5
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WP 2611 00
Figure 2. Stage 2 HPT Nozzle Lift Adapter, 2C14703
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(2) Using three screws and nuts, secure lift adapter, 2C14703, onto stage 2 HPT
nozzle aft flange. Tighten nuts to 40-60 lb in. (4.5-6.8 N·m) of torque.
WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they can
cause an injury or kill you.
(3) Lift stage 2 HPT nozzle into position. Carefully slide stage 2 HPT nozzle onto
HPT rotor assembly.
(4) Apply thread lubricant onto threads and washer faces of 136 bolts.
(5) Install brackets at locations marked at disassembly. Using bolts and nuts, secure
brackets onto flange. Boltheads face forward. Tighten nuts to 210-230 lb in.
(23.7-26.0 N·m) of torque.
(6) Install remaining bolts, spacers, and nuts. Boltheads face forward. Spacers mate
directly with boltheads. Tighten nuts to 210-230 lb in. (23.7-26.0 N·m) of torque.
B. Install stage 2 HPT rotor blades as follows (figure 1):
(1) Install stage 2 HPT rotor blade marked number 1 into dovetail slot marked
number 1. Install blade from aft side of disk.
CAUTION
Ensure stage 2 blade damper assemblies are installed at positions
as marked at disassembly. Incorrect placement will cause rotor
imbalance.
(2) Install damper assembly marked number 1 on clockwise side of number 1 blade.
Seal extension faces aft and letter F faces forward.
(3) Install remaining blades and damper assemblies in numerical order.
(4) Hold adjacent blades together at platforms and outward in dovetail slot. Seal
portion of damper assembly shall be free to move radially minimum of 0.010 inch
(0.25 mm). See figure 3. Damper portion of damper shall be free to move.
3
(5) Apply generous amount of thread lubricant onto threads and washer faces of new
self-locking nuts that secure stage 2 blade retainer.
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WP 2611 00
Figure 3. Stage 2 Blade Damper Assemblies
WARNING
Adhesive is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Use in a well-venti-
lated area.
CAUTION
Adhesive may be used to hold ring seal in place during assembly.
Ensure adhesive is applied in areas 0.5-1.5 inches (12.7-38.1 mm)
long and spacer not less than 6 inches (152.4 mm) apart.
(6) Install new ring seal into stage 2 blade retainer groove. Gap between ends of ring
seal shall be 0.10-0.15 inch (2.5-3.8 mm). If gap exceeds 0.15 inch (3.8 mm), a
piece of another ring seal may be used to fill gap. Minimum length of 2.00 inches
(50.8 mm) shall be used.
(7) Install stage 2 blade retainer onto stage 2 disk, aligning matchmarks. Using new
nuts, secure stage 2 blade retainer. Using dial indicator torque wrench, tighten
nuts to 110-120 lb in. (12.4-13.6 N·m) of torque. If run-on torque is less than
6.5 lb in. (0.7 N·m) or more than 30 lb in. (3.4 N·m), replace nut.
8 Change 6
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WP 2611 00
(8) Check clearance between aft retainer and stage 2 disk. Clearance shall be
0.002 inch (0.050 mm) maximum in areas where axial width of stage 2 blade
shank is greater than width of stage 2 disk. Clearance shall be 0.001 inch
(0.025 mm) maximum in all other areas. See figure 4.
(9) Loosen nuts one-half turn, then tighten to 110-120 lb in. (12.4-13.6 N·m) of
torque.
4
Figure 4. Stage 2 Blade Retainer Seating Check
Change 6 9/(10 Blank)
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WP 2612 00
2WP 2612 00
WORK PACKAGE
TECHNICAL PROCEDURES
STAGE 2 HIGH PRESSURE TURBINE (HPT) NOZZLE
(OFF ENGINE) REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 0
Alphabetical Index
Subject Page
Stage 2 HPT Nozzle Installation ................................................................................................. 6
Stage 2 HPT Nozzle Removal..................................................................................................... 3
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 2612 00
1. Introduction.
A. This work package contains instructions for replacing the stage 2 high pressure turbine (HPT)
nozzle when HPT module is removed from engine.
B. Remove HPT module and install, forward end down, in HPT module shipping/storage stand,
2C14193G03, and secure with plug, 2C14193P04, to retain stage 2 disk refer to WP 2610 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
High Pressure Turbine (HPT) Module Replacement WP 2610 00
Stage 2 High Pressure Turbine (HPT) Rotor Blades Replace- WP 2614 00
ment
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Stand, Shipping/Storage - HPT Module 2C14193G03
Adapter, Lift - HPT Nozzle, Stage 2 2C14703G01
Sling, Lift MES-53
4. Consumable Material.
Nomenclature Specification
Adhesive Scotch Grip 77
Dry Ice Fed Spec BB-C-104
Marking Pen Sharpie T.E.C. (Black
or Blue)
Penetrating Oil GE Spec A50TF54,
CL-A
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Nut, Self-Locking 9985M32P06 74
Seal, Ring 9331M55P01 1
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2612 00
6. Stage 2 HPT Nozzle Removal.
A. Remove stage 2 HPT rotor blades as follows (figure 1):
NOTE
The procedures in this work package for removing and installing
stage 2 HPT rotor blades are to facilitate other maintenance only. If
stage 2 HPT rotor blades require replacement, refer to WP 2614 00.
(1) Apply penetrating oil onto threads of nuts that secure stage 2 blade retainer onto
stage 2 disk. Allow penetrating oil to soak for 20 minutes.
(2) Using marking pen, matchmark stage 2 blade retainer to stage 2 disk.
1
Figure 1. Stage 2 HPT Rotor Blades
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2612 00
CAUTION
Do not move HPT rotor assembly while stage 2 blade retainer is
removed unless a minimum of 37 blade retainer nuts are installed
and tightened to 110-120 lb in. (12.4-13.5 N·m) of torque.
(3) Remove and discard nuts that secure stage 2 blade retainer. If any stud is broken,
or if any nut must be cut off, replace HPT module refer to WP 2610 00.
WARNING
Dry ice, BB-C-104: Do not let this material touch you. Low-tem-
perature skin damage. Can decrease available air. Asphyxiant.
Personal protective equipment required, especially insulated
gloves and eye protection when handling material. Use in a well-
ventilated area.
(4) Using dry ice, chill stage 2 blade retainer.
WARNING
Wear insulated gloves to prevent injury when handling cold parts.
CAUTION
Protect stage 2 disk from tool damage when prying stage 2 blade
retainer. Ensure prying tool has corner radii to prevent damage to
stage 2 blade retainer.
(5) Remove stage 2 blade retainer. Remove and discard ring seal.
CAUTION
Ensure blade damper assemblies are matchmarked accurately.
Incorrect placement at installation will cause rotor imbalance.
(6) Using marking pen, matchmark stage 2 blades to stage 2 disk. Begin with blade in
dovetail slot marked 1-1 and number all stage 2 blades consecutively in clockwise
direction. Mark number 1 through number 5 dovetail slots. Mark blade damper
assemblies, starting with number 1 at clockwise side of number 1 blade.
(7) Remove stage 2 blades and damper assemblies.
B. Remove stage 2 HPT nozzle as follows (figure 2):
2
(1) Using sling and 1-ton (907 kg) overhead hoist, position lift adapter, 2C14703,
onto stage 2 HPT nozzle aft flange.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2612 00
Figure 2. Stage 2 HPT Nozzle Lift Adapter, 2C14703
(2) Using three screws and nuts, secure lift adapter, 2C14703, onto stage 2 HPT
nozzle aft flange. Tighten nuts 40-60 lb in. (4.5-6.8 N·m) of torque.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(3) Carefully lift stage 2 HPT nozzle aft from HPT rotor assembly.
C. Inspect interstage seal honeycomb for evidence of thermal shield teeth rub into braze.
Replace HPT module if braze has been contacted.
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2612 00
7. Stage 2 HPT Nozzle Installation.
CAUTION
Ensure stage 2 HPT nozzle part number is correct per IPB,
GEK 105060, before installation, or damage to engine could result.
A. Install stage 2 HPT nozzle as follows (figure 2):
(1) If installed, remove stage 2 HPT rotor blades refer to step 6.A.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(2) Using sling and 1-ton overhead hoist, position lift adapter, 2C14703, onto stage 2
HPT nozzle aft flange.
(3) Using three screws and nuts, secure lift adapter, 2C14703, onto stage 2 HPT
nozzle aft flange. Tighten nuts to 40-60 lb in. (4.5-6.8 N·m) of torque.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(4) Lift stage 2 HPT nozzle over HPT rotor assembly. Carefully lower stage 2 HPT
nozzle onto HPT rotor assembly. Remove lift adapter.
B. Install stage 2 HPT rotor blades as follows (figure 1):
(1) Install stage 2 HPT rotor blade marked number 1 into dovetail slot marked num-
ber 1. Install blade from aft side of disk.
CAUTION
Ensure stage 2 blade damper assemblies are installed at positions as
marked at disassembly. Incorrect placement will cause rotor imbal-
ance.
(2) Install stage 2 blade damper assembly marked number 1 on clockwise side of
number 1 blade. Seal extension faces aft and letter F faces forward.
(3) Install remaining blades and damper assemblies in numerical order.
3
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2612 00
Figure 3. Stage 2 Blade Damper Assemblies
(4) Hold adjacent blades together at platforms and outward in dovetail slot. Seal
portion of damper assembly shall be free to move radially minimum of 0.010 inch
(0.25 mm). See figure 3. Damper portion of damper shall be free to move.
(5) Apply generous amount of thread lubricant onto threads and washer faces of new
nuts that secure stage 2 blade retainer.
WARNING
Adhesive is flammable and toxic to skin, eyes, and respiratory tract.
Skin and eye protection is required. Use in a well-ventilated area.
NOTE
Adhesive may be used to hold ring seal in place during assembly.
Ensure adhesive is applied in areas 0.5-1.5 inches (12.7-38.1 mm)
long and spacer not less than 6 inches (152.4 mm) apart.
(6) Install new ring seal into stage 2 blade retainer groove. Gap between ends of ring
seal shall be 0.10-0.15 inch (2.5-3.8 mm). If gap exceeds 0.15 inch (3.8 mm),
piece of another ring seal may be used to fill gap. A minimum length of
2.00 inches (50.8 mm) shall be used.
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2612 00
(7) Install stage 2 blade retainer onto stage 2 disk, aligning matchmarks. Using new
nuts, secure aft retainer. Using dial indicator torque wrench, tighten nuts to
110-120 lb in. (12.4-13.6 N·m) of torque. If run-on torque is less than 6.5 lb in.
(0.7 N·m), or more than 30 lb in. (3.4 N·m), replace nut.
(8) Check clearance between aft blade retainer and stage 2 disk. Clearance shall be
0.002 inch (0.050 mm) maximum in areas where axial width of stage 2 blade
shank is greater than width of stage 2 disk. Clearance shall be 0.001 inch
(0.025 mm) maximum in all other areas. See figure 4.
(9) Loosen nuts one-half turn, then tighten to 110-120 lb in. (12.4-13.6 N·m) of
torque.
4
Figure 4. Stage 2 Blade Retainer Seating Check
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2613 00
5
WORK PACKAGE
TECHNICAL PROCEDURES
STAGE 1 HIGH PRESSURE TURBINE (HPT) ROTOR
BLADES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 2
Page Change Page Change Page Change
No. No. No. No. No. No.
1-2 ...... 0
This WP has been DELETED
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2613 00
1. Introduction.
GE does not recommend replacing stage 1 HPT blades in the field due to the inability to
replace the HPT rim bolts without total disassembly of the rotor stage.
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WP 2614 00
5WP 2614 00
WORK PACKAGE
TECHNICAL PROCEDURES
STAGE 2 HIGH PRESSURE TURBINE (HPT) ROTOR
BLADES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 10 ...... 6
Alphabetical Index
Subject Page
Replacement Blades Selection .................................................................................................... 5
Stage 2 HPT Rotor Blades Installation........................................................................................ 7
Stage 2 HPT Rotor Blades Removal ........................................................................................... 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2614 00
1. Introduction.
A. This work package contains instructions for removing and installing the stage 2 high
pressure turbine (HPT) rotor blades.
B. Remove the low pressure turbine (LPT) module to gain access.
2. Reference Material.
Title Number
Deleted
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture, Clamp - HPT Rotor Disks 1C9444G01
Gage, Length - HPT Rotor Stage 2 Blade 2C14796G02
Program, Balance - Blade Replacement 9446M61G02
(or latest CD-Rom version)
4. Consumable Material.
Nomenclature Specification
Adhesive Scotch Grip 77
Dry Ice BB-C-104
Marking Pen Sharpie T.E.C.
(Black or Blue)
Penetrating Oil GE Spec A50TF54,
CL-A
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Nut, Self-Locking 9985M32P06 74
Seal, Ring 9331M55P01 1
2 Change 6
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WP 2614 00
6. Stage 2 HPT Rotor Blades Removal.
1
NOTE
• The following procedure allows replacement of a maximum of
five stage 2 blades without a subsequent HPT rotor balance.
• If the tube coupling nut is removed, install HPT clamp fixture,
1C9444.
A. Remove stage 2 blade retainer, figure 1, as follows:
WARNING
The stage 2 HPT disk is sensitive to nicks and scratches that
could inadvertently result from this procedure. If the stage 2 disk
is damaged, even slightly, during this procedure, the disk must be
referred to the appropriate Factory Technical Support represen-
tative for evaluation and repair recommendation. Failure to
comply may result in an uncontained engine failure, which could
cause injury or death.
(1) Apply penetrating oil onto threads of nuts that secure stage 2 blade retainer onto
stage 2 disk. Allow penetrating oil to soak for 20 minutes.
(2) Using marking pen, matchmark stage 2 blade retainer to stage 2 disk.
CAUTION
Do not move HPT rotor assembly while stage 2 blade retainer is
removed unless a minimum of 37 blade retainer nuts are installed
and tightened to 110-120 lb in. (12.4-13.6 N·m) of torque.
(3) Remove and discard nuts that secure stage 2 blade retainer. If any stud is broken,
or if any nut must be cut off, replace HPT module.
WARNING
Dry ice, BB-C-104: Do not let this material touch you. Low-tem-
perature skin damage. Can decrease available air. Asphyxiant.
Personal protective equipment required, especially insulated
gloves and eye protection when handling material. Use in a well-
ventilated area.
(4) Using dry ice, chill stage 2 blade retainer.
Change 6 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2614 00
Figure 1. Stage 2 HPT Rotor Blade Replacement
4 Change 6
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WP 2614 00
CAUTION
Protect stage 2 disk from tool damage when prying stage 2 blade
retainer. Ensure prying tool has corner radii to prevent damage to
stage 2 blade retainer.
(5) Remove stage 2 blade retainer. Remove and discard ring seal.
B. Remove stage 2 HPT rotor blades as follows:
WARNING
The stage 2 HPT disk is sensitive to nicks and scratches that
could inadvertently result from this procedure. If the stage 2 disk
is damaged, even slightly, during this procedure, the disk must
be referred to the appropriate Factory Technical Support repre-
sentative for evaluation and repair recommendation. Failure to
comply may result in an uncontained engine failure, which could
cause injury or death.
CAUTION
Ensure blade damper assemblies are matchmarked accurately.
Incorrect placement at installation will cause rotor imbalance.
(1) Position mark stage 2 blades and blade dampers to be removed and their
corresponding dovetail slot on stage 2 disk using marking pen. Mark blade
damper assemblies to be removed.
(2) Remove stage 2 blades and damper assemblies.
7. Replacement Blades Selection.
A. Measure length of removed stage 2 HPT rotor blades using gage, 2C14796.
Replacement blade length shall be within 0.010 inch (0.25 mm) of length of removed
blade but shall not exceed length of longest blade in stage.
B. Weigh removed stage 2 HPT rotor blades and record on position map (figure 2).
2
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WP 2614 00
Figure 2. HPT Stage 2 Blade/Damper Assembly Position Map
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WP 2614 00
NOTE
Replacement stage 2 HPT rotor blades shall be weighed after tip
grinding to meet length requirement. For planning purposes,
removal of 0.010 inch (0.25 mm) from blade tip will reduce blade
weight by 0.12 gram. Do not use blade weight marked on new blades
by manufacturer.
C. Weigh replacement stage 2 HPT rotor blades. Using marking pen, mark weight on
blade.
D. Select replacement stage 2 HPT rotor blades within 0.25 gram of original blade.
Blades replacing those with portions missing shall weigh within 0.25 gram of average
of two adjacent blades on each side of damaged blade. If replacement blade within
0.25 gram of original blade is not available, use blade replacement guide (figure 3).
NOTE
For a copy of GE computerized balance program and instructions
for use, contact GE customer service.
E. Calculate blade position using GE computerized balance program, 9446M61.
Mark position on replacement blade using marking pen.
3
8. Stage 2 HPT Rotor Blades Installation.
WARNING
The stage 2 HPT disk is sensitive to nicks and scratches that
could inadvertently result from this procedure. If the stage 2 disk
is damaged, even slightly, during this procedure, the disk must be
referred to the appropriate Factory Technical Support represen-
tative for evaluation and repair recommendation. Failure to
comply may result in an uncontained engine failure, which could
cause injury or death.
CAUTION
Ensure stage 2 HPT nozzle part number is correct per IPB,
GEK 105060, before installation, or damage to engine could result.
A. Install stage 2 HPT rotor blades as follows:
(1) Install stage 2 HPT rotor blade into corresponding dovetail slot. Install blade from
aft side of disk.
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WP 2614 00
Figure 3. Blade Replacement Guide
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CAUTION
Ensure stage 2 blade damper assemblies are installed at positions
as marked at disassembly. Incorrect placement will cause rotor
imbalance.
(2) Install damper assembly as marked at removal.
(3) Install remaining blades and damper assemblies.
(4) Hold adjacent blades together at platforms and outward in dovetail slot. Seal
portion of damper assembly shall be free to move radially minimum of 0.010 inch
(0.25 mm). See figure 4. Damper portion of damper assembly shall also be free to
move.
B. Install stage 2 blade retainer as follows:
(1) Apply generous amount of thread lubricant onto threads and washer faces of new
nuts that secure stage 2 blade retainer.
4
Figure 4. Stage 2 Blade Damper Assemblies
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WP 2614 00
NOTE
Adhesive may be used to hold ring seal in place during assembly.
Ensure adhesive is applied in areas 0.5-1.5 inch (12.7-38.1 mm) long
and spaced not less than 6 inches (152.4 mm) apart.
(2) Install new ring seal into stage 2 blade retainer groove. Gap between ring seal
ends shall be 0.10-0.15 inch (2.5-3.8 mm). If gap exceeds 0.15 inch (3.8 mm),
piece of another ring seal may be used to fill gap. Minimum length of 2.00 inches
(50.8 mm) shall be used.
(3) Install stage 2 blade retainer onto stage 2 disk, aligning matchmarks. Using new
nuts, secure aft retainer. Tighten nuts to 110-120 lb in. (12.4-13.6 N·m) of torque
using dial indicator torque wrench. Replace nut if run-on torque is less than
6.5 lb in. (0.7 N·m) or more than 30 lb in. (3.4 N·m).
(4) Check clearance between aft retainer and stage 2 disk. Clearance shall be
0.002 inch (0.050 mm) maximum in areas where axial width of stage 2 blade
shank is greater than width of stage 2 disk. Clearance shall be 0.001 inch
(0.025 mm) maximum in all other areas. See figure 5.
(5) Loosen nuts one-half turn, then tighten to 110-120 lb in. (12.4-13.6 N·m) of
torque.
5
Figure 5. Stage 2 Blade Retainer Seating Check
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 2710 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE TURBINE (LPT) MODULE
REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 44
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 44 ...... 6
Alphabetical Index
Subject Page
Bushing Reseating Procedure ..................................................................................................... 20
Low Pressure Turbine (LPT) Module Inspection........................................................................ 17
Low Pressure Turbine (LPT) Module Installation ...................................................................... 22
Low Pressure Turbine (LPT) Module Removal.......................................................................... 6
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2710 00
1. Introduction.
A. This work package contains instructions for removing and installing the LPT module.
B. Remove gas turbine from enclosure per WP 3010 00 and install in the maintenance dolly or
maintenance support pedestals per WP 3012 00 or WP 3013 00.
C. Disconnect and connect electrical leads and connecting tubes between LPT module and gas
turbine per SWP 1913 03.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Turbine (LPT) Module External Tubing, Har- SWP 1913 02
nesses, and Clamping
Gas Turbine in Enclosure Replacement WP 3010 00
Gas Turbine Maintenance Dolly Removal and Installation WP 3012 00
Gas Turbine/Support Pedestal Removal and Installation WP 3013 00
Low Pressure Turbine (LPT) Module in Shipping Container
Replacement WP 3017 00
Illustrated Parts Breakdown GEK 105060
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WP 2710 00
3. Support Equipment.
Nomenclature Part No.
Tool Set, Jackscrew 1C6804G04
Tool Set, Jackscrew 1C9150G02
Adapter, Sleeve - LPT Rotor Shaft 1C9316G02
Puller, LPT Module - Mid Shaft 1C9327G03
Fixture Assembly, Install/Remove - Aft Drive 1C9336G01
Shaft Nut
Fixture, Forward Restrain - LPT Rotor/Stator 1C9338G02
Deleted
Adapter Assembly, Drive - Rear 1C9609G01
Pilot, LP Mid Shaft - Aft 1C9610G01
Strongback, Lift, Turn and Restrain - LPT 1C9613G02
Module
Fixture, Seat Check - Coupling Nut, Shaft, 1C9616G01
LPT Rotor
Fixture, Start - LPT Coupling Nut 1C9617G01
Fixture, Install/Remove - Retainer Ring 1C9618G01
LPT/Mid Shaft
Fixture, Torque - LPT Shaft Coupling Nut 1C9619G02
Gage Inspection - Fan Shaft to HPT Stator 1C9620G01
Case
Collar Mid Shaft, Centering and Support 1C9622G01
Fixture, Adjustable C.G. Horizontal Lift - 1C9627G01
Heavy Purpose
Dolly, Storage, LPT Module 1C9632G01
Puller, High Force - LPT Module Mid Shaft 1C9650G01
(Alternate for 1C9327G03)
Pusher, LPT Shaft Bushing 1C9651G01
Guide Clamps 2C14693G01
Dynamometer, 10,000 lb (4,536 kg) Local Purchase
Capacity
Lifteye (0.500-13UNC-2B Thread) Local Purchase
Load Cell, 10,000 lb (4,536 kg) Capacity Local Purchase
(Alternate to Dynamometer)
Hand Pump P802 (ENERPAC)
Torque Multiplier Sweeney Model 8112B
(or equivalent)
Torque Multiplier Sweeney Model 8200
(or equivalent)
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WP 2710 00
4. Consumable Material.
Nomenclature Specification
Dry Film Lubricant GE Spec A50TF192,
CL-B
(Surfkote A-1625 or
Sandstrom 27A)
Dry Ice Fed Spec BB-C-104
Isopropyl Alcohol Fed Spec TT-I-735
Marking Pen Sharpie T.E.C.
(Black or Blue)
Penetrating Oil GE Spec A50TF54, CL-A
(L1 Liquid Wrench or
Dag 2404)
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
A. Required Material.
Nomenclature Part No. Qty
Nut, Coupling L47804P01 1
B. The following material may be required to complete this work package:
Nomenclature Part No. Qty
Bolt (Rear Drive Adapter Cover) L45045P01 28
Nut, Adapter L45017G05 1
Nut (After Shaft Cover) J626P04 7
Nut (Rear Drive Adapter Cover) J626P09 28
Ring, Retainer L47805P01 1
Ring, Shaft L45066P01 1
C. The following material may be required if a new LPT module is being installed:
Nomenclature Part No. Qty
Spacer, Ring (Shim) L47865P03 1
Spacer, Ring (Shim) L47865P04 1
Spacer, Ring (Shim) L47865P05 1
Spacer, Ring (Shim) L47865P06 1
Spacer, Ring (Shim) L47865P07 1
4 Change 6
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WP 2710 00
Nomenclature Part No. Qty
Spacer, Ring (Shim) L47865P08 1
Spacer, Ring (Shim) L47865P09 1
Spacer, Ring (Shim) L47865P10 1
Spacer, Ring (Shim) L47865P11 1
Spacer, Ring (Shim) L47865P12 1
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6. Low Pressure Turbine (LPT) Module Removal.
A. Remove aft shaft cap as follows:
(1) Remove nuts that secure aft shaft cap to adapter nut.
(2) Using four jackscrews, from tool set, 1C6804, remove aft shaft cap.
(3) Remove keyed ring.
B. Match mark and remove balance weights (bolts/spacers) if installed on aft spacer seal,
L47758, in order to install tool, 1C9609.
C. Install strongback, 1C9613, as follows (figure 1):
(1) Install rear drive adapter assembly, 1C9609 onto aft spacer seal, L47758P01.
(2) Install lifteye in shaft adapter ring, 1C9613P04.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
NOTE
The rear drive adapter, 682L262, has been replaced with spacer seal,
L47758. The rear drive adapter assembly, 1C9609, is a tool that
attaches to the spacer seal during removal. See figure 1.
(3) Using overhead hoist, lift shaft adapter ring, 1C9613P04, into position on rear
drive adapter assembly, 1C9609. Secure shaft adapter ring onto adapter assembly
with 14 equally spaced bolts and nuts. Tighten nuts to 55-65 lb ft (75-88 N·m) of
torque.
(4) Remove lifteye.
(5) Using adjustable horizontal lift fixture, 1C9627, and dynamometer or load cell
between hoist and horizontal lift fixture, lift strongback, 1C9613, into position.
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Figure 1. LPT Module Lift, Turn, and Restrain Strongback, 1C9613
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CAUTION
Do not allow the weight of the strongback to rest on the outer seal
carrier or shaft adapter ring before installing strongback retaining
screws.
(6) Secure strongback, 1C9613, onto outer seal carrier with screws and washers.
Tighten screws to 160-210 lb in. (18.1-23.7 N·m) of torque.
(7) Turn LPT rotor to align alignment hole on shaft adapter ring, 1C9613P04, with
radial slot at 10:00 o'clock position on strongback. Install quick-release pin.
(8) Install nut ring, 1C9613P06, onto shaft adapter ring, 1C9613P04. Tighten nut ring
until seated against shaft adapter ring flange.
(9) Install four lock blocks, 1C9613P05. Secure lock blocks, 1C9613P05, with
screws. Tighten screws to 420-510 lb in. (47.5-57.6 N·m) of torque.
D. Remove adapter nut as follows:
(1) Install adapter nut fixture, 1C9336, over adapter nut and secure with nuts. See
figure 3. Tighten nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
(2) Install mounting plate, 1C9619P06, over fixture assembly. Secure mounting plate,
1C9619P06, to strongback, 1C9613, with two mounting screws. Tighten
mounting screws finger-tight.
(3) Install torque multiplier, Sweeney Model 8112B/8200, or equivalent. Actuate
torque multiplier to loosen adapter nut and locking ring. Do not exceed
15,000 lb ft (20,337 N·m) of torque to loosen adapter nut.
(4) If adapter nut will not loosen with 15,000 lb ft (20,337 N·m) of torque, proceed as
follows:
(a) Remove torque multiplier, mounting plate, 1C9619P06, and adapter nut
fixture, 1C9336.
Figure 2. Deleted
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Figure 3. Aft Drive Shaft Nut Removal Fixture Assembly, 1C9336
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WARNING
Use eye protection when you cut material or parts. Particles can
cause damage to your eyes.
(b) Cut adapter nut in axial direction, two places 180 degrees apart, on top of
castellation, 1.375 inch (34.93 mm) deep. Use care not to cut into LPT rotor
shaft threads or rear drive adapter. Cut adapter nut with high speed cut-off
wheel.
(c) Install tooling and loosen adapter nut per steps (1), (2), and (3) above.
Adapter nut will split under torque and may be removed and discarded.
(5) Remove torque multiplier, mounting plate, 1C9619P06, and adapter nut fixture,
1C9336. Remove adapter nut.
E. Install guide protector, 1C9316P04, so that tabs engage slots in LPT rotor shaft. See
figure 4. Tighten retaining nut, 1C9316P03, until bottomed against rear drive
adapter/spacer seal.
F. Remove LPT coupling nut retaining ring as follows (figure 5):
(1) Using bright light, determine location of two retaining ring tooling holes. Rotate
shaft to locate these holes to 6:00 o'clock position.
(2) Using gage block, 1C9618P14, preset pins on retaining ring removal fixture,
1C9618.
(3) Install retaining ring removal fixture, 1C9618, into guide protector, 1C9316P04.
If necessary, rotate removal fixture, 1C9618, slightly to engage pins in retaining
ring tooling holes.
(4) Insert flexible borescope into guide tube at rear of retaining ring removal fixture,
1C9618. Verify engagement of pins in retaining ring tooling holes. If necessary,
reposition removal fixture to engage pins in retaining ring tooling holes.
(5) Seat retaining ring removal fixture, 1C9618, against retaining ring.
(6) Turn knurled knob of retaining ring removal fixture, 1C9618, to compress
retaining ring.
(7) Withdraw retaining ring removal fixture, 1C9618, with retaining ring. Turn
knurled knob to release retaining ring.
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Figure 4. LPT Rotor Shaft Guide Protector, 1C9316P04
Figure 5. LPT/Mid Shaft Retaining Ring Removal Fixture, 1C9618
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G. Remove LPT module forward flange attaching hardware as follows:
(1) Using marking pen and masking tape, mark location and orientation of brackets
on stage 2 high pressure turbine (HPT) nozzle aft flange.
(2) Soak attaching hardware with penetrating oil to aid in removal.
(3) Remove nuts, bolts, spacers, and brackets that secure LPT module to HPT
module.
(4) Install guide clamps, 2C14693, onto stage 2 HPT nozzle aft flange at 12:00, 3:00,
6:00, and 9:00 o'clock positions. Tighten thumbscrews.
NOTE
Thumbscrews may require retightening after the LPT flange disengages
the HPT flange.
H. Remove LPT coupling nut as follows (figure 6):
(1) Install torque tube, 1C9619P03, and torque fixture, 1C9619, through LPT rotor
shaft. Align torque tube so that teeth of tube engage slots of LPT coupling nut.
(2) Push indexing tube, 1C9619P02, forward and rotate, if necessary, to engage tab
on tube with slot in mid shaft assembly.
(3) Install mounting plate, 1C9619P06, onto strongback, 1C9613, and secure with
two mounting screws. Tighten mounting screws finger-tight.
(4) Install torque multiplier, Sweeney Model 8112B/8200, or equivalent, onto mount-
ing plate, 1C9619P06, so that splines engage splines on torque tube. Secure
torque multiplier to mounting plate, 1C9619P06, with two locking screws.
(5) Actuate torque multiplier to loosen coupling nut.
(6) Remove torque multiplier and all components of torque fixture.
(7) Using LPT coupling nut start fixture, 1C9617, remove LPT coupling nut.
If difficulty is encountered engaging locking pins into LPT coupling nut inner
snapring groove, remove LPT coupling nut as follows (figure 7):
(a) Fully retract inner sleeve of start fixture.
(b) Insert start fixture and loosen LPT coupling nut until nearly disengaged.
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Figure 6. LPT Coupling Nut Torque Fixture, 1C9619
(c) Remove start fixture and extend inner sleeve until locking pins are positioned
0.0625 inch (1.6 mm) beyond wrenching lugs.
(d) Insert start fixture so that locking pins engage LPT coupling nut inner
snapring groove.
7
(e) Loosen LPT coupling nut until disengaged from threads. Remove LPT
coupling nut and discard.
I. Separate LPT module from gas turbine as follows (figure 8):
(1) Install plunger tube, 1C9327P11, into LPT rotor shaft so that forward end of tube
seats against mid shaft assembly.
(2) Install remaining portion of LPT module mid shaft puller, 1C9327, so that slots in
adapter, 1C9327P03, slide over capscrews in sleeve adapter, 1C9316. Turn
adapter counterclockwise to lock.
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Figure 7. LPT Coupling Nut Start Fixture, 1C9617
WARNING
Serious injury can occur when applying hydraulic pressure. Eye protec-
tion is required. Relieve pressure before disconnecting lines and fittings.
NOTE
If LPT module cannot be removed using mid shaft puller, 1C9327, alternate
puller, 1C9650, may be used. Keep tools separate.
(3) Apply hydraulic pressure until LPT module moves aft approximately 0.75 inch
(19.1 mm). Ensure that LPT moves freely, indicating it is not held by press fit diameters.
If LPT module breaks free, proceed to step 4. If LPT will not move, proceed as follows:
WARNING
Dry Ice, BB-C-104: Do not let this material touch you. Low-temperature
skin damage. Can decrease available air. Asphyxiant. Personal protec-
tive equipment required, especially insulated gloves and eye protection
when handling material. Use in a well-ventilated area.
(a) Pack mid shaft with dry ice, BB-C-104 and chill for 30 minutes.
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Figure 8. LPT Module Mid Shaft Puller (Sheet 1 of 2)
Figure 8. LPT Module Mid Shaft Puller (Sheet 2 of 2)
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(b) Remove dry ice and re-try tool, 1C3927. If LPT module breaks free, proceed
to step 4. If LPT will not move proceed to step (c).
(c) Release pressure. Remove puller, 1C9327, and plunger tube, 1C9327P11
CAUTION
Use extreme caution when using tool, 1C9650. Aft threads on the
LPT shaft may be damaged during use.
(d) Install plunger tube, 1C9650P02, sheet 2, forward end into LPT shaft until aft
end of tube is inside aft face of LPT shaft.
(e) Attach horizontal adjustable lift fixture, 1C9627, to lift ring on hydraulic
cylinder and adapter, 1C9650P03, assembly.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
(f) Align large holes in adapter, 1C9650P03, with bolts of LPT rotor shaft sleeve
adapter, 1C9316P03. Push adapter against sleeve adapter and rotate hydraulic
cylinder to lock cylinder to LPT shaft.
(g) Attach hand pump to hydraulic cylinder coupler and actuate cylinder. LPT
module must move 1 inch (25.4 mm) to disengage from rabbet fit.
(h) If LPT module does not break free after reaching 5000 psig (34,474 kPa
gage), increase pressure in increments of 1000 psi (6895 kPa) until LPT mod-
ule breaks free from mid shaft. Do not exceed 10,000 psig (68,948 kPa gage).
(i) When LPT module moves freely, remove tool and visually inspect LPT
threads for any damage. Using removed engine hardware aft nut, hand-thread
nut on LPT shaft. Nut should hand-thread to mate face of aft seal adapter. If
nut will not hand-thread, fluorescent-penetrant-inspect aft threads per GEK
9250, Section 70-32-02. If damage is found, route LPT module to approved
LM6000 depot for shaft replacement.
(4) Remove LPT module mid shaft puller, 1C9327 or 1C9650.
(5) Adjust center of gravity on horizontal adjustable lift fixture, 1C9627.
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WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
(6) Using knurled nut, ensure jack assembly, 1C9448, under compressor rear frame
(CRF), is snug in place. Tighten rod-end nut one additional turn. Lift strongback,
1C9613, until dynamometer or load cell indicates combined weight of LPT
module, strongback, and lift fixture, 1C9627, approximately 8600 pounds
(3901 kg). Check pins at turbine rear frame (TRF) for easy removal. If pins cannot
be removed, readjust jack assembly. Lift strongback until dynamometer or load
cell indicates combined LPT module, strongback, and lift fixture weight again.
Repeat process until pins at TRF are not loaded. Remove pins and move LPT
module aft, taking care to level module during removal, until clear of engine.
(7) Remove shim from mid shaft rear flange. Record shim part number or thickness.
J. Install LPT module into LPT module storage dolly, 1C9632, per WP 3017 00 or install
in shipping container per WP 3017 00.
K. If LPT module will not be installed shortly, install mid shaft pilot, 1C9610, onto mid
shaft.
7. Low Pressure Turbine (LPT) Module Inspection.
NOTE
Some LPT modules contain a bushing on the aft shaft inner pilot diameter
(figure 9). Inspection of the shaft for bushing axial movement is required
prior to LPT module installation.
A. Inspect LPT aft shaft for steps on surface B (figure 10):
Inspect Max Serviceable Max Repairable Action
Steps on Surface B 0.050 in. (1.27 mm) Any amount Reseat bushing
per paragraph 8
B. Alternate Inspection - If step on surface B is present, measure axial position of aft shaft
bushing (figure 10):
Inspect Max Serviceable Max Repairable Action
Axial position of aft 0.690 in. (17.53 mm) Any amount Reseat bushing
shaft bushing per paragraph 8
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Figure 9. LPT Aft Shaft Bushing Location
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Figure 10. LPT Aft Shaft Inspection Criteria
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8. Bushing Reseating Procedure.
A. Assemble tool, 1C9651, as follows:
(1) For forward portion of tool, attach push plate (1, figure 11, Detail A) to nylon
guide (2) using three capscrews (3), provided. Thread handle (4) into push plate.
NOTE
Ensure small chamfer on backing plate (5) is located facing forward.
(2) For aft portion of tool, assemble backing plate (5) to guide rod (6). Assemble
three guide plates (7) and seven nuts (8) per figure 11
B. Reseat bushing as follows:
(1) Insert aft portion of tool, backing plate (5) first, into aft LPT shaft bore until plate
seats on aft face of bushing.
(2) Insert forward portion of tool into forward end of LPT shaft, over guide rod (6),
and seat against bushing.
(3) Thread nut (8) onto forward end of guide rod (6) and tighten with hand wrench.
NOTE
Ensure guide rod (6) is centered before applying additional torque.
(4) Tighten nut (8) against LPT aft shaft to 25 lb ft (34 N·m).
NOTE
Each turn of nut (8) is worth approximately 0.090 inch (2.3 mm).
(5) Tighten nut (8) until torque starts to dramatically increase. Back off nut, remove
tooling, and inspect bushing for correct seating.
(6) Repeat reseat procedure until bushing is fully seated.
(7) Remove forward and aft portions of tool.
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Figure 11. LPT Rotor Shaft Bushing Reseating
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9. Low Pressure Turbine (LPT) Module Installation.
A. Install strongback, 1C9613, as follows (figure 1):
(1) If removed, install rear drive adapter, 1C9609, onto aft spacer seal.
(2) Install lifteye in shaft adapter ring.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
(3) Using overhead hoist, lift shaft adapter ring into position on rear drive adapter
assembly, 1C9609. Using 14 equally spaced bolts and nuts, secure adapter ring
onto adapter assembly. Tighten nuts to 55-65 lb ft (75-88 N·m) of torque.
(4) Remove lifteye.
(5) Using adjustable horizontal lift fixture, 1C9627, and dynamometer or load cell
between hoist and horizontal lift fixture, lift strongback, 1C9613, into position.
CAUTION
Do not allow the weight of the strongback to rest on the outer seal
carrier or shaft adapter ring before installing strongback retaining
screws.
(6) Secure strongback, 1C9613, onto outer seal carrier with screws and washers.
Tighten screws to 160-210 lb in. (18.1-23.7 N·m) of torque.
(7) Turn LPT rotor to align alignment hole on shaft adapter ring with radial slot at
10:00 o'clock position on strongback. Install quick-release pin.
(8) Install nut ring, 1C9613P06, onto shaft adapter ring. Tighten nut until seated
against shaft adapter ring flange.
(9) Install four lock blocks, 1C9613P05. Secure lock blocks, 1C9613P05, with
screws. Tighten screws to 420-510 lb in. (47.5-57.6 N·m) of torque.
B. If installed, remove forward restrain fixture, 1C9338.
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NOTE
If same LPT module, stage 2 HPT nozzle, and combustion chamber
are installed, disregard step C.
C. Determine required thickness of LPT shim as follows:
(1) Calculate dimension A as follows, using figure 12 and worksheet from figure 13:
(a) Thread parallel bar, 1C9620P02, onto LP mid shaft. Bar shall be tight against
LPT rotor shaft seating flange (surface AH) of LP mid shaft.
(b) Position centering collar and support fixture, 1C9622, so support frame,
1C9622P02, feet interface with HPT stator case aft flange. If necessary, lower
adjusting plate, 1C9622P03, by turning hand knob, 1C9622P08. Align
countersunk holes in frame feet and flange holes. Insert capscrews into
countersinks and secure onto forward side of stator case flange with washers
and nuts, sheet 2. Tighten nuts to 70-110 lb in. (7.9-12.4 N·m) of torque.
(c) Use hand knob, 1C9622P08, to raise adjusting plate, 1C9622P03, to bring
LPTR mid shaft to required level. If necessary, apply slight upward force at
aft end of shaft. Tighten nuts (figure 12, sheet 1).
(d) Using vernier depth gage, 1C9620P04, take four drop measurements from aft
surface of parallel bar (surface AH) to HPT stator support aft face at 2:00,
4:00, 8:00, and 10:00 o'clock position locations by turning the assembled core
section 90 degrees after each measurement. Record measurements as
dimension A1.
(e) Average four A1 measurements and record as dimension A2.
(f) Subtract thickness of parallel bar (stamped on bar) from A2 and record as
dimension A3.
NOTE
The 0.093 inch (2.36 mm) equals stage 2 shroud support thickness
(0.063 inch [1.60 mm]) and depth of HPT stator support cooling
scallops (0.030 inch [0.76 mm]).
(g) Subtract 0.093 inch (2.36 mm) from A3 and record as dimension A.
(2) Obtain dimension J02 from LPT module build record or as marked on LPT case.
Dimension J02 is marked on case at 9:00 o'clock position, adjacent to T48 probe
boss, approximately 2.5 inches (63.5 mm) aft of case forward flange.
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Figure 12. Dimension A Measurement (Sheet 1 of 2)
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Figure 12. Dimension A Measurement (Sheet 2 of 2)
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Figure 13. LPT Installation Worksheet
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(3) Determine difference between J02 and dimension A. Subtract J02 from
dimension A. Record result as calculated shim thickness. See LPT installation
worksheet on figure 13.
(4) Calculate shim thickness based on figure 13. Record result as calculated shim
thickness.
(5) Remove parallel bar, 1C9620P02 and centering collar, 1C9622.
(6) Use calculated shim thickness to select required LPT shim from table 1. If
calculated shim is not within range of shims shown, select shim closest to
calculated shim thickness.
Table 1. LPT Shim Thickness
Thickness Shim P Number
Inch (mm) (PN L47865)
0.098-0.102 (2.49-2.59) P03
0.108-0.112 (2.74-2.84) P04
0.118-0.122 (3.00-3.10) P05
0.128-0.132 (3.25-3.35) P06
0.138-0.142 (3.51-3.61) P07
0.148-0.152 (3.76-3.86) P08
0.158-0.162 (4.01-4.11) P09
0.168-0.172 (4.27-4.37) P10
0.178-0.182 (4.52-4.62) P11
0.188-0.192 (4.78-4.88) P12
D. Determine calculated LPT seating check dimension AJ as follows. See figure 14 and
worksheet on figure 13.
(1) Obtain a new coupling nut.
(2) Measure length of new coupling nut at one location. Mark point of measurement
on aft face with marking pen. Record as dimension THK.
(3) Measure thickness of shim at four equally spaced locations. Average four
measurements and record as dimension AST.
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Figure 14. Calculate LPT Seating Check Measurements
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(4) Measure thickness of LPT shaft seating flange at four equally spaced locations.
Average four measurements and record as dimension ST.
(5) Add dimensions THK, AST, and ST and record as dimension TAS.
(6) Measure length from end of LP mid shaft to surface AH at four equally spaced
locations. Average four measurements and record as dimension AG.
(7) Determine difference between dimensions TAS and AG. Record result as
calculated dimension AJ.
E. Install guide clamps, 2C14693, onto HPT stator case aft flange at 12:00, 3:00, 6:00,
and 9:00 o'clock positions. Tighten thumbscrews. See figure 15.
F. Install LPT module as follows:
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
CAUTION
Ensure a new coupling nut is used, or damage during gas turbine
operation may result.
(1) Clean threads and seating surface of new LPT coupling nut and threads, seating
surface, aft pilot, and splines of mid shaft assembly using clean cloth with solvent.
(2) Apply solid film lubricant to mid shaft spline (figure 16).
(a) Apply lubricant to full length of spline bottom and flank surfaces to an
approximate thickness of 0.0005-0.002 inch (0.013-0.05 mm). Full coverage
required.
(b) Excess lubricant allowed on spline major diameter and within 0.5 inch
(13 mm) and 0.15 inch (3.8 mm) of spline ends.
(c) Apply solid film lubricant to aft pilot diameter.
(d) Excess lubricant not allowed on shaft mating Surface F or on shaft threads.
(e) Allow lubricant to dry for one hour before mating LPT module.
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Figure 15. LPT Module Guide Installation
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Figure 16. LPT Coupling Nut Inspection
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(3) Apply generous coat of thread lubricant to threads of mid shaft assembly.
(4) Apply an even coat of thread lubricant to forward face of LPT coupling nut.
(5) Lubricate preformed packing with thread lubricant and install in preformed
packing groove of mid shaft duct.
(6) If installed, remove mid shaft pilot, 1C9610.
NOTE
Ensure there is no thread lubricant on shim
(7) Install shim into LPT rotor shaft until shim contacts seating shoulder. Align shim
so that maximum thickness is located 180 degrees from H mark on fan midshaft
(8) Rotate LPC rotor to align forward drive adapter M mark with M mark on spacer
seal/rear drive adapter. See figure 17.
(9) With strongback,1C9613, installed and dynamometer or load cell installed, lift
LPT module and trial fit module to mid shaft splines. Move LPT module
forward, align and initiate spline engagement. Do not force module. After spline
alignment is verified, pull module away.
WARNING
Use thermal gloves when you move or touch hot parts. Hot parts
can cause injury.
(10) Heat inside pilot diameter of LPT rotor shaft to 325 to 400°F (162.8 to 204.4°C)
using dry heat.
CAUTION
• Do not remove hoist loading until pins at TRF are fully loaded.
• Ensure dynamometer or load cell does not indicate less or more
than weight observed in step (9).
(11) Move LPT module forward aligning M marks. Carefully engage splines of mid
shaft assembly. Ensure that M marks remain aligned.
(12) Install several bolts at each clock position to secure LPT module forward flange to
stage 2 nozzle aft flange. Tighten bolts finger tight.
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Figure 17. Rear Drive Adapter M Mark
(13) Install dolly mounting pins at TRF. Snug TRF dolly posts to take weight of LPT module
by adjusting threaded risers. Tighten pedestal retaining nuts to 70-80 lb ft. (95-108 N·m)
of torque
G. Install guide protector, 1C9316P04, so that tabs engage slots in LPT rotor shaft
(figure 18).
H. Start LPT coupling nut onto mid shaft assembly using LPT coupling nut start fixture,
1C9617. See figure 19.
I. Install LPT shaft coupling nut torque fixture, 1C9619, as follows (figure 20):
(1) Install torque tube, 1C9619P03, of torque fixture, 1C9619, through LPT rotor shaft.
Align torque tube so that teeth of tube engage slots of LPT coupling nut.
(2) Push indexing tube, 1C9619P02, forward and rotate, if necessary, to engage tab on tube
with slot in mid shaft assembly.
(3) Install mounting plate, 1C9619P06, onto strongback fixture, 1C9613, and secure with
two mounting screws. Tighten mounting screws finger-tight.
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Figure 18. LPT Rotor Shaft Guide Protector, 1C9316P04
(4) Install torque multiplier, Sweeney Model 8112B/8200, or equivalent, onto mount-
ing plate, 1C9613P06, so that splines engage torque tube splines. Secure torque
multiplier to mounting plate, 1C9619P06, with two locking screws.
J. Tighten LPT coupling nut as follows:
(1) Tighten LPT coupling nut to 4,000 lb ft (5,423 N·m) of torque. Allow shaft
temperature to normalize. Break torque on LPT coupling nut.
(2) Tighten LPT coupling nut to 2,000 lb ft (2,712 N·m) of torque. Record wrench
angle at this torque.
CAUTION
Do not exceed 7,500 lb ft (10,169 N·m) maximum torque or a maximum
wrench angle of 30 degrees from angle recorded in step (2).
(3) Continue tightening to wrench angle 26 degrees beyond wrench angle recorded in
step (2). Do not exceed maximum torque value of 7,500 lb ft (10,169 N·m).
(4) Check alignment of LPT coupling nut and mid shaft assembly slots.
(5) Continue tightening until slots align. Marks on tool must align or retaining ring
cannot be installed. Do not exceed maximum torque of 7,500 lb ft (10,169 N·m)
or maximum angle of 30 degrees beyond wrench angle recorded in step (2).
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Figure 19. LPT Coupling Nut Installation
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Figure 20. LPT Shaft Coupling Nut Torque Fixture, 1C9619
(6) Remove torque multiplier and all components of torque fixture, 1C9619.
K. Check LPT module installation using seat check fixture, 1C9616, as follows
(figures 21 and 22):
(1) Secure gage master, 1C9616P03, to seat check fixture, 1C9616, with
thumbscrew. Set dial indicator to zero. Remove gage master from seat check
fixture.
(2) Position seat check fixture, 1C9616, into LPT in order to measure from marked
LPT coupling nut castellation aft surface. Hold firmly in place.
NOTE
A negative reading indicates the LPT coupling nut is forward of the
LP mid shaft end. A positive reading indicates the LPT coupling nut
is aft of the LP mid shaft end.
(3) Read coupling nut position directly from dial indicator and record as measured
dimension AJ. See figure 22 and worksheet on figure 13.
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Figure 21. LPT Coupling Nut Seating Check
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Figure 22. LPT Seating Check Dimension AJ
(4) Measured dimension AJ must be 0.002-0.010 inch (0.05-0.25 mm) less than
calculated dimension AJ. If dimension AJ is not with in limits, proceed as
follows:
(a) Verify seat check fixture, 1C9616, with gage master, 1C9616P03, and check
LPT module installation per steps (1) through (3). Check all calculations used
to determine calculated dimension AJ.
(b) If measured dimension AJ is still not within limits, this indicates that LPT
module is not correctly installed. Remove LPT module and check dimensions
per steps C and D. Reinstall LPT module and check installation per this
paragraph.
L. Install LPT coupling nut retaining ring, as follows (figure 23).
(1) Install retaining ring onto pins of retainer ring installation fixture, 1C9618.
(2) Turn knurled knob of retainer ring installation fixture, 1C9618, to compress
retaining ring.
(3) Insert retaining ring into LPT rotor coupling nut and mid shaft assembly slots.
(4) Turn knurled knob of retainer ring installation fixture, 1C9618, to release ring.
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Figure 23. LPT Coupling Nut Retaining Ring Installation
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(5) Optional: Insert flexible borescope into guide tube at rear of retainer ring
installation fixture, 1C9618, to verify retaining ring is seated in coupling nut.
(6) Rotate retainer ring installation fixture, 1C9618, slightly and pull aft to remove
from LPT shaft.
M. Remove guide clamps, 2C14693, from HPT stator case.
N. Lubricate bolt threads with thread lubricant. Install nuts, bolts, spacers, and brackets
that secure LPT module to HPT module. Tighten nuts to 210-230 lb in.
(23.7-26.0 N·m) of torque. Refer to SWP 1913 03.
O. Remove guide protector, 1C9316P04, from LPT rotor shaft.
P. If adapter nut was removed, install adapter nut as follows (figure 24):
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
(1) Using isopropyl alcohol, clean threads and mating surfaces of adapter nut and LPT
rotor shaft. Inspect adapter nut threads to ensure threads are free of damage and
high metal.
(2) Apply thread lubricant onto threads and forward face of adapter nut and onto
threads of LPT rotor shaft.
CAUTION
Adapter nut shall be able to be tightened by hand.
(3) Install adapter nut onto LPT rotor shaft. Hand-tighten nut.
(4) Install adapter nut fixture, 1C9336, over adapter nut and secure with nuts. Tighten
nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
(5) Install mounting plate, 1C9619P06, over adapter nut fixture, 1C9336. Secure
mounting plate onto strongback, 1C9613, with mounting screws. Tighten
mounting screws finger-tight.
(6) Install torque multiplier, Sweeney Model 8112B/8200, or equivalent.
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Figure 24. Rear Drive Adapter Nut Removal/Installation
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(7) Tighten adapter nut as follows:
(a) Seat adapter nut to 2,000 lb ft (2,712 N·m) of torque. Loosen adapter nut.
(b) Tighten adapter nut to 250 lb ft (339 N·m) above run-on torque. Record
wrench angle at this torque.
(c) Continue tightening to wrench angle 21 degrees beyond wrench angle
recorded in step (b).
(d) Check alignment of adapter nut and LPT rotor shaft slots.
CAUTION
Do not exceed maximum torque value of 8,500 lb ft (11,525 N·m) or
a maximum angle of 24 degrees from wrench angle recorded in
step (b).
(e) Continue tightening until adapter nut slots align with LPT rotor shaft slots.
Do not exceed maximum of 8,500 lb ft (11,525 N·m) or maximum angle of 24
degrees from wrench angle recorded in step (b).
(8) Remove torque multiplier, mounting plate, 1C9619P06, and adapter nut fixture,
1C9336.
Q. Remove strongback, 1C9613, as follows (figure 26):
(1) Remove bolts that secure lock blocks, 1C9613P05, to strongback, 1C9613.
Remove lock blocks.
(2) Remove nut ring, 1C9613P06.
CAUTION
Do not allow the weight of the strongback to rest on the outer seal
carrier or shaft adapter ring after removing strongback retaining
screws.
(3) Remove washers and screws that secure strongback, 1C9613, to outer seal carrier.
Figure 25. Deleted
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Figure 26. LPT Module Lift, Turn, and Restrain Strongback, 1C9613
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WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or kill you.
(4) Move strongback, 1C9613, aft away from LPT module. Lower strongback,
1C9613, forward end down, onto pallet or store on LPT module storage dolly,
1C9632. Remove quick-release pin securing strongback onto adjustable
horizontal lift fixture, 1C9627. Remove lift fixture and dynamometer or load cell
from overhead hoist.
(5) Install lifteye in shaft adapter ring, 1C9613P04. Connect an overhead hoist to
lifteye.
(6) Remove nuts and bolts that secure shaft adapter ring, 1C9613P04, to rear drive
adapter assembly, 1C9609. Lower shaft adapter ring to pallet. Remove lifteye.
R. Reassemble balance weights (bolts/spacers) and install per match marks on aft spacer
seal, L47758, if previously removed. Torque to Standard Practice requirement per
GEK 9250.
S. Install keyed ring.
T. Install aft shaft cap and secure with nuts. Tighten nuts to 55-70 lb in. (6.2-7.9 N·m) of
torque.
U. Install electrical leads and tubing per SWP 1913 03.
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5WP 2711 00
WORK PACKAGE
TECHNICAL PROCEDURES
REAR DRIVE ADAPTER OR AFT SEAL SPACER
REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 16
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 16 ...... 4
Alphabetical Index
Subject Page
Aft Adapter Nut Installation ....................................................................................................... 14
Rear Drive Adapter or Aft Seal Spacer Installation.................................................................... 8
Rear Drive Adapter or Aft Seal Spacer Removal ....................................................................... 4
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1. Introduction.
A. This work package contains instructions for removing and installing a rear drive adapter or an
aft seal spacer.
B. This work package also allows switching of a rear drive adapter with an aft seal spacer or an aft
seal spacer with a rear drive adapter.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Turbine (LPT) Module Replacement WP 2710 00
3. Support Equipment.
Nomenclature Part No.
Torque Fixture (PA/PB), Shaft Coupling Nut, 1C9309G03
Low Pressure Turbine (LPT)
Puller, LPT Module Midshaft 1C9327G03
Strongback Fixture (PA/PB), Lift, Turn and 1C9328G01
Restrain, Low Pressure Turbine
Puller Plate, Aft Drive Adapter 1C9329G02
Nut Fixture, Aft Drive Shaft 1C9336G01
Assembly, Rear Drive Adapter 1C9609G01
Strongback Fixture (PC/PD), Lift, Turn and 1C9613G02
Restrain, Low Pressure Turbine
Torque Fixture, LPT Shaft Coupling Nut 1C9619G01
Lift and Remove Fixture, Aft Seal Spacer 1C9642G01
Lift and Remove Fixture, Aft Seal Spacer 1C9643G01
Torque Multiplier Sweeney Model 8112B
(or equivalent)
Torque Multiplier Sweeney Model 8200
(or equivalent)
Depth Gage, Vernier
Depth Micrometer
Torque Wrench, Advanced Hydraulics, Model
AH-1043
Heat Gun
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4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol TT-I-735
Marking Pen Sharpie T.E.C.
(Black or Blue)
Safety Cable 736L680G01
Safety Wire R297P04
Thread Lubricant GP460 (GE Spec
A50TF201)
5. Expendable Material.
None required.
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6. Rear Drive Adapter or Aft Seal Spacer Removal.
A. Remove aft adapter nut per GEK 105059, WP 2710 00
NOTE
• For rear drive adapter configuration, perform step B. and skip
step C. For aft seal spacer configuration models, skip step B. and
perform step C
• Due to space constraints in package, use of Advanced Hydraulics
Model AH-1043 hydraulic torque wrench is recommended.
B. Remove rear drive adapter as follows:
(1) Using marking pen, matchmark rear drive adapter to LPT rotor shaft and rear
drive adapter to rear drive adapter flange cover.
(2) Remove bolts and self-locking nuts securing rear drive adapter flange cover to
rear drive adapter. Remove rear drive adapter flange cover. Retain rear drive
adapter flange cover, bolts, and self-locking nuts for reuse.
(3) Install reaction plate, 1C9329P04 (figure 1), into LPT rotor shaft.
1
(4) Install LPT module midshaft puller, 1C9327, onto drive adapter puller plate,
1C9329P02, by sliding midshaft puller slots over puller plate capscrews and
turning LPT module midshaft puller counterclockwise to lock.
WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they
can cause an injury or death.
(5) Using overhead hoist attached to LPT module midshaft puller lift ring, position
drive adapter puller plate, P02, onto rear drive adapter. Using hex nuts,
MS51972-6, and slabbed head bolts, 1C9613P07, obtained from strongback
fixture, 1C9613, secure drive adapter puller plate to rear drive adapter. Do not
install bolts in three holes at 12:00 o'clock position.
(6) Using three capscrews, MS35308-446, and hex nuts, MS51972-6, secure fixture,
1C9643, to drive adapter puller plate, 1C9329P02, and rear drive adapter. Attach
overhead hoist to fixture.
(7) Install hydraulic pressure source to LPT module midshaft puller, 1C9327.
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Figure 1. Rear Drive Adapter Removal
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WARNING
Serious injury can occur when applying hydraulic pressure. Eye
protection is required. Relieve pressure before disconnecting
lines and fittings.
(8) Apply hydraulic pressure until rear drive adapter is free from LPT rotor shaft.
(9) Release hydraulic pressure.
(10) Remove rear drive adapter and tooling.
C. Remove aft seal spacer as follows:
(1) Using capscrews, NAS1352-8-36 (figure 2), flat washers, AN960-C816, under
screwheads, and hex nuts, MS51971-5, install rear drive adapter onto aft seal
spacer.
(2) Install reaction plate, 1C9329P04, into LPT rotor shaft.
(3) Install LPT module midshaft puller, 1C9327, onto drive adapter puller plate,
1C9329P02, by sliding midshaft puller slots over puller plate capscrews and
turning LPT module midshaft puller counterclockwise to lock.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or death.
(4) Using overhead hoist attached to LPT module midshaft puller, 1C9327, lift ring,
position drive adapter puller plate, 1C9329P02, on rear drive adapter assembly,
1C9609. Using hex nuts, MS51972-6, and slabbed head bolts, 1C9613P07,
obtained from strongback fixture, 1C9613, secure drive adapter puller plate to rear
drive adapter assembly. Do not install bolts in three holes at 12:00 o’clock
position.
(5) Using three capscrews, MS35308-446, and hex nuts, MS51972-6, secure fixture,
1C9643, to drive adapter puller plate, 1C9329P02. Attach overhead hoist to
fixture sling link.
(6) Install hydraulic pressure source to LPT module midshaft puller, 1C9327.
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Figure 2. Aft Seal Spacer Removal
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WARNING
Serious injury can occur when applying hydraulic pressure. Eye
protection is required. Relieve pressure before disconnecting
lines and fittings.
(7) Apply hydraulic pressure until aft seal spacer is free from LPT rotor shaft.
(8) Release hydraulic pressure.
(9) Remove aft seal spacer and tooling.
(10) Using isopropyl alcohol, clean thread and splines of LPT rotor shaft.
(11) Using marking pen, mark area of key slot of balance piston on LPT rotor shaft
splines. Move mark to most aft point of LPT rotor shaft.
7. Rear Drive Adapter or Aft Seal Spacer Installation.
A. Install aft seal spacer/rear drive adapter as follows:
(1) Calculate aft seal spacer/rear drive adapter installation measurement as follows:
NOTE
Refer to figure 3 for rear drive adapter measurements and
figure 4 for aft seal spacer measurements.
(a) Measure stack-up thickness of aft seal spacer or rear drive adapter. Record
as dimension AB (figure 5).
3
2
(b) Measure stack-up thickness of adapter nut. Record as dimension AC
(figure5).
(c) Measure drop dimension from LPT shaft aft tang to balance piston aft
surface. Record as dimension AD, Figure 5.
(d) Add dimension AB to dimension AC and subtract sum from dimension AD.
Record as calculated dimension AF (figure 5).
(2) If installed, matchmark rear drive adapter flange cover to rear drive adapter using
marking pen. Remove rear drive adapter flange cover from rear drive adapter.
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Figure 3. LM6000 PA/PB Balance Piston Installation Dimensions
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Figure 4. LM6000 PC/PD Balance Piston Installation Dimensions
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Figure 5. Balance Piston/Rear Drive Adapter Installation Worksheet
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NOTE
To install rear drive adapter, proceed to substep (3). To install
aft seal spacer, proceed to substep (4).
(3) Attach drive adapter puller plate, 1C9329P02, and fixture, 1C9643, to rear drive
adapter as follows (figure 1):
(a) Using capscrews, MS35308-446, and hex nuts, MS51972-6, secure lifting
plate, 1C9643P02, and drive adapter puller plate, 1C9329P02, to rear drive
adapter.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or death.
(b) Attach hoist to sling link and raise rear drive adapter to the vertical position.
(c) If CG adjustment is required, loosen jamnuts, MS35691-75, and move lifting
plate, 1C9643P02, in direction required. Tighten jamnuts when correct
position is attained.
(d) Proceed to step 5. to install rear drive adapter.
(4) Attach fixture, 1C9642, as follows (figure 6):
4
(a) Using capscrews, .375-24 UNF-3A X 1.75 inch long, and flat washers,
MS9321-12, secure lifting plate, 1C9642P02, to three balance weight holes
on aft flange of aft seal spacer.
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or death.
(b) Attach hoist to sling link and raise aft seal spacer to vertical position.
(c) If CG adjustment is required, loosen jamnuts, MS35691-75, and move CG
adjusting plate, 1C9642P03, in direction required. Tighten jamnuts when cor-
rect position is attained.
(d) Proceed to step 5 to install aft seal spacer.
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Figure 6. LM6000 Aft Seal Spacer Lift and Remove Fixture, 1C9642
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WARNING
Use thermal gloves when you move or touch hot or cold parts.
Hot or cold parts can cause injury.
(5) Heat aft seal spacer or rear drive adapter using heat gun to 350°F (176.6°C) for
30 minutes minimum.
CAUTION
Assure balance piston slot marking is identified on LPT rotor shaft
prior to installation of adapter, or incorrect installation may occur.
(6) Install aft seal spacer or rear drive adapter to the LPT rotor shaft, aligning key on
rear drive adapter to slot mark on LPT rotor shaft. Remove tooling used to
position aft seal spacer or rear drive adapter.
8. Aft Adapter Nut Installation.
A .For aft seal spacer configurations only, install rear drive assembly adapter, 1C9609,
onto aft seal spacer using capscrews, NAS1352-8-36, flat washers, AN960-C816, and
hex nuts, MS51971-5 (figure 2).
WARNING
Always use approved equipment and procedures to lift parts.
Stay out from below loads. If the parts accidentally move or fall,
they can cause an injury or death.
B. Lift shaft adapter ring, 1C9328P04 or 1C9613P04 (figure 7), into position on rear
drive assembly or rear drive adapter assembly, 1C9609, using an overhead hoist.
Secure shaft adapter ring with eight equally spaced slabbed head bolts, 1C9328P07
or 1C9613P07 and hex nuts, MS51972-6. Tighten nuts to 55-65 lb ft (74.6-88.1 N·m)
of torque.
5
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
C. Clean retaining nut and rotor shaft threads with isopropyl alcohol.
D. Lightly coat threads and forward face of adapter nut and threads of LPT rotor shaft
with thread lubricant.
E. Install adapter nut onto LPT rotor shaft. Tighten adapter nut finger-tight.
F. Install adapter nut fixture, 1C9336, over studs in adapter nut and secure using seven
nuts, MS51972-1. Tighten nuts to 55-70 lb in. (6.3-7.9 N·m) of torque.
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Figure 7. Adapter Nut Installation
Change 4 15
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G. Install mounting plate, 1C9309P06 for rear drive adapter configurations or 1C9619P06
for aft seal spacer configurations, over adapter nut fixture, 1C9336. Secure mounting
plate to shaft adapter ring, 1C9328P04 or 1C9613P04, using mounting screws,
1C9309P07 or 1C9619P07. Tighten mounting screws finger-tight.
H. Install torque multiplier onto adapter nut fixture, 1C9336, and mounting plate,
1C9309P06 or 1C9619P06.
I. Tighten adapter nut as follows:
(1) Seat adapter nut to 2,000 lb ft (2,711 N·m) of torque. Loosen adapter nut.
(2) Tighten adapter nut to 250 lb ft (339 N·m) above run-on torque. Record wrench
angle at this torque.
(3) Continue tightening to wrench angle 21 degrees beyond wrench angle recorded in
substep (2).
(4) Check alignment of adapter nut and LPT rotor shaft slots.
CAUTION
Do not exceed maximum torque value of 8,500 lb ft (11,524 N·m) of
torque or maximum angle of 24 degrees from wrench angle
recorded in substep (2) or damage to LPT module may result.
(5) Continue tightening until adapter nut slots align with LPT rotor shaft slots. Do not
exceed maximum of 8,500 lb ft (11,524 N·m) of torque or maximum angle of
24 degrees beyond wrench angle recorded in substep (2).
J. Remove torque multiplier, mounting plate, 1C9309P06 or 1C9619P06, shaft adapter
ring, 1C9328P04 or 1C9613P04, and adapter nut fixture, 1C9336.
K. Using depth micrometer, measure from rear face of adapter nut to rear face of LPT
rotor shaft. Record as measured dimension AF (figure 5).
L. Compare measured dimension AF to calculated dimension AF. The two values shall be
within 0.005 inch (0.13 mm) of each other.
M. Install keyed ring to adapter nut and LPT rotor shaft.
N. Using self-locking nuts, J626P04, secure aft shaft cap to LPT rotor shaft. Tighten
self-locking nuts to 55-70 lb in. (6.5-7.9 N·m) of torque.
O. If rear drive adapter flange cover was removed in step 6.B.(2), secure rear drive
adapter flange cover to rear drive adapter using bolts, L45045P01 and self-locking
nuts, J626P09B or J626P09D. Ensure matchmarks on rear drive adapter flange cover
and rear drive adapter align. Tighten self-locking nuts to 480-570 lb in.
(54.3-64.4 N·m) of torque.
16 Change 4
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WP 2810 00
2WP 2810 00
WORK PACKAGE
TECHNICAL PROCEDURES
RADIAL DRIVE SHAFT REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 10 ...... 0
Alphabetical Index
Subject Page
Radial Drive Shaft Installation.................................................................................................... 6
Radial Drive Shaft Removal ....................................................................................................... 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2810 00
1. Introduction.
This work package contains instructions for removing and installing the radial drive shaft.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Tool Set, Radial Drive Shaft 1C6361G01
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P028 1
Packing, Preformed J221P240 1
Packing, Preformed J221P908 1
Ring, Retaining 705B276P5 1
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6. Radial Drive Shaft Removal.
A. Remove radial drive shaft spacer as follows:
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(1) Position waste fluid container under transfer gearbox drain. Remove drain plug
and drain oil. See figure 1. Remove and discard preformed packing from drain
plug.
(2) Lubricate new preformed packing with lubricating oil and install on drain plug.
(3) Install drain plug into transfer gearbox assembly. Tighten drain plug to
60-80 lb in. (6.8-9.0 N·m) of torque. Safety-wire drain plug.
(4) Place waste fluid container under radial cover assembly. Remove nuts and
washers that secure radial cover assembly. Using jackscrews, carefully remove
radial cover assembly. Remove and discard preformed packing.
1
Figure 1. Drain Plug and Radial Cover Assembly
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(5) Using flat-tipped screwdriver, unwind retaining ring from groove in bottom of
bevel gearshaft.
(6) Assemble radial drive shaft tool, 1C6361, as follows (figure 2):
2
(a) Turn handnut counterclockwise until no threads are visible at end of rod
between handnut and T-handle.
(b) Place sleeve onto rod against handnut.
(c) Assemble washer, expandable plug, and retainer onto socket head screw.
Ensure retainer fits over end of expandable plug. Install socket head screw
into end of rod and tighten finger-tight.
(d) Turn handnut clockwise until seated snugly against sleeve.
(7) Insert radial drive shaft tool, 1C6361, into gearbox opening so expandable plug
goes through center of radial drive shaft spacer. Lift tool upwards as far as
possible.
(8) Hold T-handle of rod and turn handnut clockwise to expand expandable plug
snugly inside spacer.
CAUTION
Radial drive shaft may fall suddenly after removal of radial drive
shaft spacer. Hand should be held under gearbox opening to prevent
damage to drive shaft.
(9) Pull down on radial drive shaft tool, 1C6361, to remove radial drive shaft spacer
from bevel gearshaft. Remove radial drive shaft, by hand, if radial drive shaft
comes out with radial drive shaft spacer.
(10) Loosen handnut and remove radial drive shaft spacer from radial drive shaft tool,
1C6361.
(11) Remove preformed packing from radial drive shaft spacer. Remove and discard
preformed packing.
(12) Remove socket head screw, retainer, expandable plug, and washer from radial
drive shaft tool, 1C6361.
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Figure 2. Radial Drive Shaft Spacer Removal Using Radial Drive Shaft Tool, 1C6361
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NOTE
If radial drive shaft fails to come out during spacer removal, remove
radial drive per paragraph B.
B. Remove radial drive shaft as follows (figure 3):
3
(1) Assemble collet and draw screw onto end of rod. Tighten draw screw finger-tight.
(2) Insert radial drive shaft tool, 1C6361, into gearbox opening so that collet enters
center of radial drive shaft.
(3) Hold T-handle of rod and turn handnut clockwise to expand collet snugly into
radial drive shaft.
(4) Pull down on radial drive shaft tool, 1C6361, to remove radial drive shaft from
radial drive shaft tool, 1C6361.
NOTE
Radial drive shaft binding during removal indicates possible transfer
gearbox assembly misalignment.
(5) Loosen handnut and remove radial drive shaft from radial drive shaft tool,
1C6361.
7. Radial Drive Shaft Installation.
A. Install radial drive shaft as follows:
(1) Assemble radial drive shaft tool, 1C6361, as follows (figure 3):
(a) Turn handnut counterclockwise until no threads are visible at end of rod
between handnut and T-handle. Install sleeve onto rod against handnut.
(b) Assemble collet onto draw screw. Install draw screw into end of rod and
tighten finger-tight.
(2) Insert radial drive shaft tool, 1C6361, into end of radial drive shaft opposite
grooved shear section. Hand-tighten handnut.
(3) Install radial drive shaft into transfer gearbox opening. Raise radial drive shaft as
far as possible. Slight turning may be required to engage splines.
(4) Move radial drive shaft up and down to ensure free axial movement. No binding is
allowed.
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Figure 3. Radial Drive Shaft Removal Using Radial Drive Shaft Tool, 1C6361
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(5) If binding exists, perform the following:
(a) Loosen jamnuts on mount links until locking devices are disengaged.
CAUTION
Ensure locking devices remain disengaged during adjustment of
mount links.
(b) Adjust mount links to obtain free movement of drive shaft.
(c) Tighten jamnuts to 270-290 lb in. (30.5-32.8 N·m) of torque.
(d) Move radial drive shaft up and down to ensure that no binding exists.
(e) Check mount links for proper engagement of rod-end bearing threads by
trying to insert a No. 56 drill (0.055-inch [1.4 mm] diameter) through witness
hole at each end of turnbuckle. Drill shall not pass through.
(f) Safety-wire jamnuts to locking devices.
CAUTION
If left unsupported, radial drive shaft may fall out of transfer gearbox.
(6) Loosen handnut and carefully withdraw radial drive shaft tool, 1C6361.
(7) Remove draw screw and collet from rod.
B. Using radial drive shaft tool, 1C6361, install radial drive shaft spacer and retaining
ring, as follows (figure 4):
4
(1) Install new retaining ring into flanged end of retaining ring shaft.
(2) Using ring pusher, push retaining ring through retaining ring shaft to within
0.125-0.250 in. (3.18-6.35 mm) of end of shaft. Align cutout sections of shaft and
pusher.
(3) Install shaft and pusher over rod and sleeve.
(4) Assemble washer, expandable plug, and retainer onto socket head screw. Ensure
retainer fits over end of expandable plug. Install socket head screw into end of rod
and tighten finger-tight.
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Figure 4. Radial Drive Shaft Spacer and Retaining Ring Installation Using Radial Drive Shaft Tool, 1C6361
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WP 2810 00
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(5) Lubricate new preformed packing with lubricating oil and install onto radial drive
shaft spacer.
(6) Install radial drive shaft spacer onto expandable plug. Hand-tighten handnut.
(7) Insert radial drive shaft spacer into bottom of radial drive shaft. Turn radial drive
shaft tool cutouts to face aft.
(8) Raise radial drive shaft tool, 1C6361, to position radial drive shaft and radial drive
shaft spacer as far into gearbox as possible.
(9) Hold T-handle and push retaining ring shaft upwards, as far as possible, and hold.
(10) Release T-handle and push ring pusher upwards, as far as possible, to position
retaining ring into groove of bevel gear.
(11) Pull down on radial drive shaft tool, 1C6361, to seat radial drive shaft spacer
against retaining ring.
(12) Loosen handnut and remove radial drive shaft tool, 1C6361.
CAUTION
An improperly installed retaining ring can cause radial drive shaft
failure and gas turbine shutdown.
(13) Ensure retaining ring is properly installed in bevel gearshaft groove.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(14) Lubricate new preformed packing with lubricating oil and install onto radial cover
assembly. See figure 1.
(15) Using washers and nuts, install radial cover assembly onto bottom of transfer
gearbox assembly. Tighten nuts to 55-70 lb in. (6.2-7.9 N·m) of torque.
10
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WP 2811 00
WP 2811 00
WORK PACKAGE
TECHNICAL PROCEDURES
TRANSFER GEARBOX ASSEMBLY REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1-9 ...... 6
10 Blank . . . . . . 6
Alphabetical Index
Subject Page
Transfer Gearbox Assembly Installation .................................................................................... 7
Transfer Gearbox Assembly Removal ........................................................................................ 3
Change 6 1
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WP 2811 00
1. Introduction.
A. This work package contains instructions for removing and installing the transfer gearbox
assembly.
B. Deleted.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Front Frame Module External Tubing, Harnesses, and Clamp- SWP 1913 01
ing
Radial Drive Shaft Replacement WP 2810 00
3. Support Equipment.
Nomenclature Part No.
Jack, Lowering - Engine Components 1C5654G03
Guide, Expandable Bushing 1C6119G01
Fixture, Instl/Removal - Access Gearbox, 1C6872G01
Horiz
Pusher, Bolt - Front Frame/TGB Fwd Mtg 1C6892G01
Bracket
4. Consumable Material.
Nomenclature Specification
Molybdenum Disulfide Lubricant GE Spec A50TF79
5. Expendable Material.
None required.
2 Change 6
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6. Transfer Gearbox Assembly Removal.
A. Remove radial drive shaft per WP 2810 00.
B. Disconnect electrical leads and connecting tubes between transfer gearbox and gas turbine
per SWP 1913 01.
CAUTION
When loosening hose clamp to reposition and retighten around radial drive
shaft housing, ensure clamp is not placed directly on beaded end of adapter.
C. Loosen lower flexible housing clamp. See figure 1. Reposition clamp higher on flexible
housing and retighten to prevent clamp from falling.
1
D. Install installation/removal fixture, 1C6872 (figure 2), onto jack, 1C5654 (figure 3).
E. Position jack, 1C5654, under transfer gearbox assembly. Raise jack to position
installation/removal fixture, 1C6872, against transfer gearbox assembly.
F. Continue raising jack, 1C5654, to support weight of transfer gearbox assembly.
G. Secure strap around forward side of transfer gearbox assembly between forward mount and
flexible housing adapter. Set floor locks on jack, 1C5654.
CAUTION
Ensure bolts are free turning prior to removal. Forceful removal of bolts
may damage gas turbine or transfer gearbox assembly.
H. Remove three nuts, washers, and bolts that secures transfer gearbox assembly onto links.
I. Remove nut from expandable bushing that secure front end of transfer gearbox assembly
onto gas turbine.
J. Retract screw of pusher, 1C6892, then engage clevis end of pusher around head of expand-
able bushing. See figure 4. Ensure that pusher is seated squarely against gearbox mount. Turn
pusher screw slowly to push out expandable bushing.
2
WARNING
Keep hands clear of moving parts when lowering jack or personal
injury could occur.
K. Lower jack, 1C5654, slowly until transfer gearbox assembly is clear of gas turbine.
L. Release floor locks on jack, 1C5654, and remove transfer gearbox assembly.
Change 6 3
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Figure 1. Transfer Gearbox Assembly Replacement
4 Change 6
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1
Figure 2. Accessory Gearbox Installation and Removal Fixture, 1C6872
Change 6 5
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Figure 3. Engine Components Lowering Jack, 1C5654
6 Change 6
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Figure 4. Expandable Bushing Removal Using Pusher, 1C6892
7. Transfer Gearbox Assembly Installation.
A. Install installation/removal fixture, 1C6872 (figure 2), onto jack, 1C5654 (figure 3). Set floor
locks on jack.
B. Install transfer gearbox assembly onto installation/removal fixture, 1C6872.
C. Secure strap around forward end of transfer gearbox assembly between forward mount and
flexible housing adapter.
D. Release floor locks on jack, 1C5654. Position transfer gearbox assembly under gas turbine.
Set floor locks on jack.
E. Raise jack, 1C5654, to position transfer gearbox assembly. Align mounting points and flexi-
ble housing adapter with flexible housing.
Change 6 7
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NOTE
It may be necessary to release floor locks on jacks to position transfer
gearbox assembly. Always engage floor locks before continuing gear-
box raising operation.
F. Raise gearbox until flexible housing adapter is engaged in flexible housing and
forward mount expandable bushing can be installed.
G. Screw guide, 1C6119, onto expandable bushing until seated. See figure 5. Do not
apply pressure that could expand bushing. Insert expandable bushing, with guide, into
forward gearbox mount so bolthead is to left (aft looking forward). If necessary, lightly
tap bolthead with plastic mallet.
H. Remove guide. Install nut, but do not tighten at this time.
I. Apply molybdenum disulfide lubricant onto spherical bearings of mount and sway
links.
J. Adjust gearbox, as required, to connect aft left mount link onto gearbox mount. See
figure 1. Install bolt, washer, and nut so that bolthead faces left (aft looking forward).
Do not tighten nut at this time.
3
Figure 5. Expandable Bushing Installation Using Guide, 1C6119
8 Change 6
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K. Adjust gearbox, as required, to connect right mount link onto gearbox mount. Ensure
sleeve bushing is present. Install bolt, washer, and nut so that bolthead faces right
(aft looking forward). Do not tighten nut at this time.
L. Connect sway link onto gearbox mount. Install bolt, washer, and nut so bolthead faces
aft. Do not tighten nut at this time.
M. Tighten forward mount bushing nut to 125-133 lb ft (169.5-180.3 N·m) of torque.
N. Tighten remaining mount and sway link nuts to 125-133 lb ft (169.5-180.3 N·m) of
torque.
WARNING
Keep hands clear of moving parts when lowering jack or per-
sonal injury could occur.
O. Disconnect strap from around transfer gearbox assembly. Slowly lower jack, 1C5654.
Release floor locks and roll jack clear of gas turbine.
CAUTION
Radial drive shaft housing cuts caused by clamps can occur when
clamp is installed on housing surface directly over beaded end of
adapter. Ensure clamps are installed per figure 1.
P. Ensure that flexible housing is seated over flexible housing adapter. Loosen and lower
clamp to secure flexible housing to flexible housing adapter. Ensure clamp is placed
on housing per dimensions shown in view A of figure 1. Tighten clamps at both ends
of flexible housing to 35-45 lb in. (4.0-5.1 N·m) of torque. If clamps are not tight at
45 lb in. (5.1 N·m), discard clamp and replace with new clamp. Housing material shall
not bulge around clamp.
Q. Connect electrical leads and connecting tubes between transfer gearbox and gas tur-
bine per SWP 1913 01.
R. Install radial drive shaft per WP 2810 00.
Change 6 9/(10 Blank)
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WP 2812 00
2WP 2812 00
WORK PACKAGE
TECHNICAL PROCEDURES
SPUR GEARSHAFT ASSEMBLIES REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 24
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 23 ...... 0
24 Blank . . . . . . 0
Alphabetical Index
Subject Page
Free Rotation Check.................................................................................................................... 21
Fuel Pump Spur Gearshaft Assembly Installation ...................................................................... 7
Fuel Pump Spur Gearshaft Assembly Removal.......................................................................... 5
Manual Drive Spur Gearshaft Installation .................................................................................. 16
Manual Drive Spur Gearshaft Removal...................................................................................... 14
Preparation For Maintenance ...................................................................................................... 4
Starter Spur Gearshaft Assembly Installation ............................................................................. 13
Starter Spur Gearshaft Assembly Removal................................................................................. 11
Variable Geometry Hydraulic Pump Spur Gearshaft Installation............................................... 20
Variable Geometry Hydraulic Pump Spur Gearshaft Removal .................................................. 18
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 2812 00
1. Introduction.
A. This work package contains instructions for removing and installing transfer gearbox assembly
spur gearshaft assemblies.
B. Remove gearbox mounted accessories as required to gain access per WPs 1812 00, 1814 00,
and 1815 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Geometry Hydraulic Pump Replacement WP 1812 00
Pneumatic Starter Replacement WP 1814 00
Hydraulic Starter and Distributor Assembly Replacement WP 1815 00
Accessory Gearbox Carbon Seals Replacement WP 2813 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Tool Set, Assy/Disassy - Gearbox 1C6986G01
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Marking Pen Sharpie T.E.C.
(Black or Blue)
Petrolatum Fed Spec VV-P-236
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
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5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Round 9009M74P01 1
Gasket, Seal J219P02A 1
Keywasher 9009M32P01 3
Packing, Preformed J221P014 2
Packing, Preformed J221P134 1
Packing, Preformed J221P145 1
Packing, Preformed J221P163 1
Packing, Preformed J221P166 1
Packing, Preformed J221P170 1
Packing, Preformed J221P175 1
Packing, Preformed J221P216 2
Packing, Preformed J221P240 1
Packing, Preformed J221P904 2
Packing, Preformed J221P908 1
Ring, Internal Retaining 705B276P10 1
Ring, Retaining 705B276P5 1
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6. Preparation For Maintenance.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tion tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
A. Place waste fluid container under transfer gearbox drain. Remove drain plug and drain
oil. Discard preformed packing. See figure 1.
B. Lubricate new preformed packing with petrolatum and install onto drain plug.
C. Install drain plug into transfer gearbox assembly. Tighten drain plug to 270-300 lb in.
(30.5-33.9 N·m) of torque.
1
Figure 1. Preparation for Maintenance
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7. Fuel Pump Spur Gearshaft Assembly Removal.
CAUTION
Ensure connecting fitting is restrained when loosening coupling
nut. Failure to comply may result in part damage.
A. Disconnect seal drain manifold from fitting on fuel pump adapter. Reposition seal
drain manifold.
B. Remove fitting and discard preformed packing.
C. If fuel pump cover is used, perform the following:
(1) Remove bolts, washers, fuel pump cover, and gasket from fuel pump drive pad,
if required. Discard gasket. See figure 2.
2
(2) Remove aft shaft seal assembly. Remove and discard preformed packing.
(3) Remove nut, adapter, and preformed packing from aft shaft seal assembly.
Discard preformed packing.
D. Remove safety wire. Remove bolts and washers that secure fuel pump adapter
assembly onto gearbox housing assembly.
CAUTION
Do not allow fuel pump adapter assembly flange to cock during
removal. Turning jackscrews evenly in small increments will prevent
cocking.
E. Using three jackscrews from tool set, 1C6986, remove fuel pump adapter assembly
and preformed packing. Discard preformed packing.
F. Using arbor press, remove spur gearshaft assembly from fuel pump adapter assembly.
CAUTION
If mating seal ring requires replacement, carbon seal must also be
replaced. Refer to WP 2813 00 for carbon seal replacement.
G. Remove mating seal ring.
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WP 2812 00
Figure 2. Fuel Pump Spur Gearshaft Assembly Replacement
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CAUTION
Inner and outer races of roller bearing must be kept together as a
matched set, or bearing damage may occur.
H. Using arbor press, remove roller bearing inner race and rollers from spur gearshaft
assembly.
I. Remove forward shaft seal assembly from spur gearshaft assembly. Remove and
discard preformed packing.
J. Remove nut, adapter, and preformed packing from forward shaft seal assembly.
Discard preformed packing.
K. Unbend keywasher tabs. Remove bolts and keywashers that secure bearing housing.
Discard keywashers.
L. Using puller from tool set, 1C6986, remove bearing housing and roller bearing outer
race as follows (figure 3):
3
(1) Install puller so three puller feet engage bearing housing.
(2) Turn knurled knob CW to secure puller feet into place.
(3) Tighten jamnut against spreader bar.
(4) Slide hammer against knurled knob with enough force to disengage bearing
housing from gearbox housing assembly.
(5) Loosen jamnut and turn knurled knob CCW to release bearing housing from
puller feet.
8. Fuel Pump Spur Gearshaft Assembly Installation.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tion tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
A. Using lubricating oil, lubricate bearing housing and gearbox housing bore. Install
bearing housing into gearbox housing bore. Using nylon drift and soft face hammer,
tap bearing housing until seated. See figure 3.
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WP 2812 00
Figure 3. Typical Bearing Housing Removal Using Puller from Tool Set, 1C6986
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CAUTION
• Ensure prebent tabs of keywasher contact CCW against bearing
housing ear with zero clearance. Do not use force or distort
prebent tab of keywasher into position.
• Do not loosen bolt to position a flat on the bolthead adjacent to
the tab.
B. Install bolts and new keywashers (figure 2). Tighten bolts to 33-37 lb in. (3.7-4.2 N·m)
of torque. Determine if flat on bolthead is adjacent to tab of keywasher. If necessary,
continue to tighten bolt to a maximum of 40 lb in. (4.5 N·m) of torque, until flat on
bolthead is adjacent to tab. Bend tab into position. See figure 4.
C. Lubricate new preformed packing with petrolatum and install onto forward shaft seal
assembly. See figure 2.
D. Install adapter and nut onto forward shaft seal assembly. Tighten nut to 190-230 lb in.
(21.5-26.0 N·m) of torque.
4
Figure 4. Typical Keywasher Installation
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E. Lubricate new preformed packing with petrolatum and install onto forward shaft seal
assembly.
F. Install forward shaft seal assembly into fuel pump spur gearshaft assembly.
G. Using arbor press, install roller bearing inner race and rollers onto spur gearshaft
assembly.
H. Install mating seal ring so tangs engage slots on roller bearing.
I. Using arbor press, install spur gearshaft assembly into fuel pump adapter assembly.
J. Apply light coat of petrolatum onto roller bearing rollers. Push rollers toward inner
race to minimize roller circle diameter.
K. Install two guide pins from tool set, 1C6986, into fuel pump drive pad.
L. Lubricate new preformed packing with petrolatum and install into groove of fuel pump
adapter assembly.
M. Carefully hold spur gearshaft assembly centered in gearbox bore and move assembly
inward to engage guide pins and roller bearing. Rotate gearshaft slightly to engage
spur gears.
CAUTION
Ensure gear teeth mesh properly and gears rotate freely to avoid
damaging gears.
N. Install five bolts and washers. Tighten bolts evenly, in small increments, to draw fuel
pump adapter assembly onto gearbox housing.
O. Perform free rotation check per paragraph 15.
P. Remove guide pins and install remaining bolts and washers. Tighten all bolts to
55-70 lb in. (6.2-7.9 N·m) of torque. Safety-wire bolts.
Q. If fuel pump cover is used, perform the following:
(1) Lubricate new preformed packing with petrolatum and install onto aft shaft
seal assembly.
(2) Install adapter and nut onto aft shaft seal assembly. Tighten nut to 190-230 lb in.
(21.5-26.0 N·m) of torque.
(3) Lubricate new preformed packing with petrolatum and install onto aft shaft
seal assembly.
10
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WP 2812 00
(4) Install aft shaft seal assembly into fuel pump spur gearshaft assembly.
(5) Using bolts, install new round gasket and cover onto fuel pump adapter assembly.
Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
R. Lubricate new preformed packing with petrolatum and install onto fitting.
S. Install fitting into fuel pump adapter. Tighten fitting to 135-150 lb in. (15.3-16.9 N·m)
of torque.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
T. Connect seal drain manifold onto fitting. Tighten coupling nut to 135-150 lb in.
(15.3-16.9 N·m) of torque.
9. Starter Spur Gearshaft Assembly Removal.
A. Remove safety-wire. Remove bolts and washers that secure starter adapter assembly
onto gearbox housing assembly. See figure 5.
5
Figure 5. Starter Spur Gearshaft Assembly Replacement
11
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WP 2812 00
CAUTION
Do not allow starter adapter assembly flange to cock during removal.
Turning jackscrews evenly in small increments will prevent cocking.
B. Using three jackscrews from tool set, 1C6986, remove starter adapter assembly and
preformed packing. Discard preformed packing.
C. Using arbor press, remove spur gearshaft assembly from starter adapter assembly.
CAUTION
If mating seal ring requires replacement, carbon seal must also be
replaced. Refer to WP 2813 00 for carbon seal replacement.
D. Remove mating seal ring.
CAUTION
Inner and outer races of roller bearing must be kept together as a
matched set, or bearing damage may occur.
E. Using arbor press, remove roller bearing inner race and rollers from spur gearshaft
assembly.
F. Remove and discard retaining ring.
G. Unbend keywasher tabs. Remove bolts and keywashers that secure bearing housing.
Discard keywashers.
H. Using puller from tool set, 1C6986, remove bearing housing and roller bearing outer
race as follows (figure 3):
(1) Install puller so three puller feet engage bearing housing.
(2) Turn knurled knob CW to secure puller feet into place.
(3) Tighten jamnut against spreader bar.
(4) Slide hammer against knurled knob with enough force to disengage bearing
housing from gearbox housing assembly.
(5) Loosen jamnut and turn knurled knob CW to release bearing housing from puller
feet.
12
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WP 2812 00
10. Starter Spur Gearshaft Assembly Installation.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tion tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
A. Lubricate bearing housing and gearbox housing bore with lubricating oil. Install
bearing housing to gearbox housing bore. Using nylon drift and soft face hammer, tap
bearing housing until seated. See figure 5.
CAUTION
• Ensure prebent tabs of keywasher contact CCW against bearing
housing ear with zero clearance. Do not use force or distort
prebent tab of keywasher into position.
• Do not loosen bolt to position a flat on the bolthead adjacent to
the tab.
B. Install bolts and new keywashers. Tighten bolts to 33-37 lb in. (3.7-4.2 N·m) of
torque. Determine if flat on bolthead is adjacent to tab of keywasher. If necessary,
continue to tighten bolt to a maximum of 40 lb in. (4.5 N·m) of torque until flat on
bolthead is adjacent to tab. Bend tab into position. See figure 4.
C. Install new retaining ring into forward groove of starter spur gearshaft assembly.
See figure 5.
D. Using arbor press, install roller bearing inner race and rollers onto starter spur
gearshaft assembly.
E. Install mating seal ring so tangs engage slots on roller bearing.
F. Using arbor press, install spur gearshaft assembly into starter adapter assembly.
G. Lubricate new preformed packing with petrolatum and install into groove of starter
adapter assembly.
H. Apply light coat of petrolatum onto roller bearing rollers. Push rollers toward inner
race to minimize roller circle diameter.
I. Install two guide pins from tool set, 1C6986, into starter drive pad.
13
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WP 2812 00
J. Carefully hold spur gearshaft assembly centered in gearbox bore and move assembly
inward to engage guide pins. Rotate gearshaft slightly to engage gear teeth with idler
gear. Continue pushing to engage bearing rollers with outer race. Using soft face
hammer, tap assembly gently until starter adapter assembly is seated.
K. Remove guide pins and secure starter adapter assembly with bolts and washers.
Tighten bolts finger-tight.
L. Perform free rotation check per paragraph 15
M. Tighten starter adapter assembly retaining bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
Safety-wire bolts.
11. Manual Drive Spur Gearshaft Removal.
A. Remove bolt and clamp that secures scavenge tube and hose assembly onto manual
drive pad cover plate. See figure 6.
6
B. Remove nut, bolt, and clamp that secures scavenge tube and hose assembly onto low
pressure drain hose.
C. Remove bolts that secure scavenge tube and hose assembly onto boss on gearbox
assembly. Remove and discard gasket.
D. Disconnect scavenge tube and hose assembly coupling nut from oil tube assembly.
Remove scavenge tube and hose assembly.
E. Using marking pen, position mark electrical brackets. Remove nuts and washers that
secure manual drive adapter assembly onto gearbox housing assembly. Reposition
electrical brackets.
CAUTION
Do not allow manual drive adapter assembly flange to cock during removal.
Turning jackscrews evenly in small increments will prevent cocking.
F. Using three jackscrews from tool set, 1C6986, remove manual drive adapter assembly
and preformed packing. Discard preformed packing.
CAUTION
If mating seal ring requires replacement, carbon seal must also be
replaced. Refer to WP 2813 00 for carbon seal replacement.
G. Remove mating seal ring.
14
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WP 2812 00
Figure 6. Manual Drive Spur Gearshaft Replacement
15
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WP 2812 00
CAUTION
Inner and outer races of roller bearing must be kept together as a
matched set, or bearing damage may occur.
H. Using arbor press, remove roller bearing inner race and rollers from spur gearshaft
assembly.
I. Using arbor press, remove spur gearshaft assembly from manual drive adapter
assembly.
J. Unbend keywasher tabs. Remove bolts and keywashers that secure bearing housing.
Discard keywashers.
K. Using puller from tool set, 1C6986, remove bearing housing and roller bearing outer
race as follows (figure 3):
(1) Install puller so three puller feet engage bearing housing.
(2) Turn knurled knob CW to secure puller feet into place.
(3) Tighten jamnut against spreader bar.
(4) Slide hammer against knurled knob with enough force to disengage bearing
housing from gearbox housing assembly.
(5) Loosen jamnut and turn knurled knob CCW to release bearing housing from
puller feet.
12. Manual Drive Spur Gearshaft Installation.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
A. Lubricate bearing housing and gearbox housing bore with lubricating oil. Install
bearing housing to gearbox housing bore. Using nylon drift and soft face hammer, tap
bearing housing until seated. See figure 6.
16
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WP 2812 00
CAUTION
• Ensure prebent tabs of keywasher contact CCW against bearing
housing ear with zero clearance. Do not use force or distort prebent
tab of keywasher into position.
• Do not loosen bolt to position a flat on the bolthead adjacent to
the tab.
B. Install bolts and new keywashers. Tighten bolts to 33-37 lb in. (3.7-4.2 N·m) of
torque. Determine if flat on bolthead is adjacent to tab of keywasher. If necessary,
continue to tighten bolt to a maximum of 40 lb in. (4.5 N·m) of torque until flat on
bolthead is adjacent to tab. Bend tab into position. See figure 4.
C. Using arbor press, install roller bearing inner race and rollers onto manual drive spur
gearshaft assembly. See figure 6.
D. Install mating seal ring so tangs engage slots on roller bearing.
E. Using arbor press, install manual drive spur gearshaft assembly into manual drive
adapter assembly.
F. Lubricate new preformed packing with petrolatum and install into groove of manual
drive adapter assembly.
G. Apply light coat of petrolatum onto roller bearing rollers. Push rollers toward inner
race to minimize roller circle diameter.
H. Install two guide pins from tool set, 1C6986, into manual drive pad.
I. Carefully hold manual drive spur gearshaft assembly centered in gearbox bore and
move assembly inward to engage guide pins and roller bearing. Rotate gearshaft
slightly to engage spur gears.
CAUTION
Ensure gear teeth mesh properly and gears rotate freely to avoid
damaging gears.
J. Position electrical brackets as marked at removal. Install five bolts and washers.
Tighten bolts evenly, in small increments, to draw manual drive adapter assembly
onto gearbox housing.
K. Perform free rotation check per paragraph 15
L. Remove guide pins and install remaining bolts and washers. Tighten all bolts to
55-70 lb in. (6.2-7.9 N·m) of torque. Safety-wire bolts.
17
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M. Install new gasket onto scavenge tube and hose assembly. Using bolts, secure
scavenge tube and hose assembly onto boss on gearbox assembly. Tighten bolts to
33-37 lb in. (3.7-4.2 N·m) of torque.
N. Connect scavenge tube and hose assembly coupling nut onto oil tube assembly.
Tighten coupling nut to 650-770 lb in. (73.4-87.0 N·m) of torque.
O. Install clamp onto scavenge tube and hose assembly. Using bolt and nut, secure clamp
to clamp on low pressure drain hose. Tighten nut to 33-37 lb in. (3.7-4.2 N·m) of
torque.
P. Install clamp onto scavenge tube and hose assembly. Using bolt, secure clamp to
manual drive adapter assembly. Tighten bolt to 33-37 lb in. (3.7-4.2 N·m) of torque.
13. Variable Geometry Hydraulic Pump Spur Gearshaft Removal.
A. Remove safety-wire. Remove bolts and washers that secure variable geometry
hydraulic pump adapter onto variable geometry pump drive pad. See figure 7
7
Figure 7. Variable Geometry Hydraulic Pump Spur Gearshaft Replacement
18
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WP 2812 00
CAUTION
Do not allow variable geometry hydraulic pump adapter flange to
cock during removal. Turning jackscrews evenly in small increments
will prevent cocking.
B. Using three jackscrews from tool set, 1C6986, remove variable geometry hydraulic
pump adapter and preformed packing. Discard preformed packing.
C. Using arbor press, remove spur gearshaft assembly from variable geometry hydraulic
pump adapter.
CAUTION
If mating seal ring requires replacement, carbon seal must also be
replaced. Refer to WP 2813 00 for carbon seal replacement.
D. Remove mating seal ring.
CAUTION
Inner and outer races of roller bearing must be kept together as a
matched set, or bearing damage may occur.
E. Remove roller bearing inner race and rollers from spur gearshaft assembly.
F. Unbend keywasher tabs. Remove bolts and keywashers securing bearing and housing.
Discard keywashers.
G. Using puller from tool set, 1C6986, remove bearing housing and roller bearing outer
race as follows (figure 3):
(1) Install puller so three puller feet engage bearing housing.
(2) Turn knurled knob CW to secure puller feet in place.
(3) Tighten jamnut against spreader bar.
(4) Slide hammer against knurled knob with enough force to disengage bearing
housing from gearbox housing assembly.
(5) Loosen jamnut and turn knurled knob CCW to release bearing housing from
puller feet.
19
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WP 2812 00
14. Variable Geometry Hydraulic Pump Spur Gearshaft Installation.
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tion tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
A. Lubricate bearing housing and gearbox housing bore with lubricating oil. Install
bearing housing to gearbox housing bore. Using nylon drift and soft face hammer, tap
bearing housing until seated.
CAUTION
• Ensure prebent tabs of keywasher contact CCW against bearing
housing ear with zero clearance. Do not use force or distort
prebent tab of keywasher into position.
• Do not loosen bolt to position a flat on the bolthead adjacent to
the tab.
B. Install bolts and new keywashers. Tighten bolts to 33-37 lb in. (3.7-4.2 N·m) of torque.
Determine if flat on bolthead is adjacent to tab of keywasher. If necessary, continue to
tighten bolt to a maximum of 40 lb in. (4.5 N·m) of torque until flat on bolthead is
adjacent to tab. Bend tab into position. See figure 4.
C. Using arbor press, install roller bearing inner race and rollers onto spur gearshaft.
D. Install mating seal ring so that tangs engage slots on roller bearing.
E. Using arbor press, install spur gearshaft assembly into variable geometry hydraulic
pump adapter.
F. Lubricate new preformed packing with petrolatum and install into groove of variable
geometry hydraulic pump adapter.
G. Apply light coat of petrolatum onto roller bearing rollers. Push rollers toward inner
race to minimize roller circle diameter.
H. Install two guide pins from tool set, 1C6986, into variable geometry hydraulic pump
drive pad.
I. Carefully hold spur gearshaft assembly centered in gearbox bore and move assembly
inward to engage guide pins and roller bearing. Rotate gearshaft slightly to engage
spur gears.
20
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WP 2812 00
CAUTION
Ensure gear teeth mesh properly and gears rotate freely to
avoid damaging gears.
J. Install six bolts and washers. Tighten evenly, in small increments, to draw variable
geometry hydraulic pump adapter into gearbox housing.
K. Perform free rotation check per paragraph 15
L. Remove guide pins and install remaining bolts and washers. Tighten all bolts to
55-70 lb in. (6.2-7.9 N·m) of torque. Safety-wire bolts.
15. Free Rotation Check.
A. Remove horizontal drive shaft as follows (figure 8):
(1) Remove nuts and washers that secure horizontal cover onto transfer gearbox
housing assembly.
(2) Tap horizontal cover with nylon drift and soft face hammer. Remove horizontal
cover and preformed packing. Discard preformed packing.
8
Figure 8. Horizontal Drive Shaft Removal and Installation
21
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NOTE
If more access space is required for internal retaining ring or horizontal
drive shaft removal, perform step (3). If access space for ring or shaft
removal is adequate, proceed to step (4).
(3) Remove nuts and washers that secure radial cover assembly. Using two
0.250-28 UNF-3B jackscrews, remove radial cover assembly. Remove and
discard preformed packing.
(4) Remove internal retaining ring from groove on inside forward end of bevel
gearshaft. Discard internal retaining ring.
(5) Remove horizontal drive shaft.
B. Perform free rotation check as follows:
(1) Remove nuts, washers, cover plate, and preformed packing to gain access to
manual drive to check free rotation of newly installed gearshaft. Discard
preformed packing.
(2) Insert 3/4-inch drive extension into manual drive gearshaft.
(3) Turn manual drive gearshaft CW and ensure gears mesh properly and no binding
exists.
(4) Lubricate new preformed packing with petrolatum and install onto cover plate.
(5) Install cover plate onto manual drive adapter assembly. Secure with washers and
nuts. Tighten nuts to 190-230 lb in. (21.5-26.0 N·m) of torque.
C. Install horizontal drive shaft as follows (figure 8):
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tion tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(1) Apply light coat of lubricating oil to splines of horizontal drive shaft. Install drive
shaft, small spline aft, through opening in front of transfer gearbox housing into
bevel gearshaft. Align splines and push drive shaft through bevel gearshaft.
(2) Install new internal retaining ring into groove on inside forward end of bevel
gearshaft.
22
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(3) Lubricate new preformed packing with petrolatum and install on horizontal cover.
(4) Install horizontal cover onto front of transfer gearbox housing. Secure with
washers and nuts. Tighten nuts to 33-37 lb in. (3.7-4.2 N·m) of torque.
(5) If radial cover assembly was removed, lubricate new preformed packing with
petrolatum and install onto radial cover assembly. Using washers and nuts, install
radial cover assembly onto bottom of transfer gearbox housing. Tighten nuts to
55-70 lb in. (6.2-7.9 N·m) of torque.
23/(24 Blank)
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WP 2813 00
0WP 2813 00
WORK PACKAGE
TECHNICAL PROCEDURES
ACCESSORY GEARBOX CARBON SEALS
REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 1
Alphabetical Index
Subject Page
Accessory Gearbox Carbon Seals Installation ............................................................................ 6
Accessory Gearbox Carbon Seals Removal................................................................................ 3
Change 1 1
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WP 2813 00
1. Introduction.
A. This work package contains instructions for removing and installing accessory gearbox
carbon seals.
B. Remove starter as required to gain access per WP 1814 00 or WP 1815 00.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Pneumatic Starter Replacement WP 1814 00
Hydraulic Starter and Distributor Assembly Replacement WP 1815 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture Set, Mating Seal Removal 1C8182G01
Guide Pins (Qty 3, 0.190-32 by 1.0 inch Locally Fabricated
bolt with head removed)
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
Petrolatum Fed Spec VV-P-236
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Round 9608M12P04 1
Keywasher 9009M32P01 9
Packing, Preformed J221P129 2
Packing, Preformed J221P138 1
Packing, Preformed J221P140 2
Packing, Preformed 9365M41P229 1
2 Change 1
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6. Accessory Gearbox Carbon Seals Removal.
A. Remove carbon seal as follows (figure 1):
1
(1) If installed, remove coupling clamp or bolts and washers, cover, and gasket from
applicable drive pad. Discard gasket.
(2) Unbend keywasher tabs.
NOTE
Seal retainer is used at starter pad only.
(3) Remove bolts, keywashers, and seal retainer. Discard keywashers.
NOTE
Some carbon seal configurations contain three slots on the inner
face of the flange midway between the bolt holes to aid in seal
removal. If slots are present, proceed to step (5).
(4) Rotate carbon seal by inserting pin of offset driver from fixture set, 1C8182, into
bolthole of seal flange and tap lightly with light hammer until seal tangs overlap
housing boss.
CAUTION
Use care to prevent cocking carbon seal or damaging housing during
removal.
(5) Remove carbon seal from gearbox housing bore using prybar from fixture set,
1C8182, to apply leverage.
(6) Remove packing from gearbox housing bore using pick set from fixture set,
1C8182. Discard preformed packing.
(7) Prior to removal of mating seal ring, obtain drop from gearbox face to mating seal
ring surface. Use this reading for reference at reinstallation of mating seal ring.
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Figure 1. Accessory Gearbox Carbon Seals
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CAUTION
If carbon seal is replaced, the mating seal ring shall also be replaced.
If carbon seal is reused, the mating seal ring shall also be reused.
B. Remove mating seal ring as follows (figure 2):
NOTE
Tool numbers 1C8182P02 through P05 are used at starter pad. Tool
numbers 1C8182P10 through P13 are used at fuel pump pad and
auxiliary accessory drive pad.
(1) Turn screw, 1C8182P06, counterclockwise to end of travel to retract pusher plate,
1C8182P05 or P11.
(2) Slide outer sleeve, 1C8182P04 or P12, back to allow fingers of inner sleeve,
1C8182P03 or P10, to expand.
(3) Insert tool into seal cavity until plastic stop, 1C8182P02 or P13, contacts mating
seal ring.
2
Figure 2. Mating Seal Ring Removal Tool, 1C8182
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(4) Slide outer sleeve over inner sleeve closing flexible fingers over mating seal ring.
(5) Turn screw clockwise until mating seal ring is pulled free of shaft.
(6) Remove tool and slide outer sleeve back to release mating seal ring.
(7) Remove packing from seal ring packing groove. Discard packing.
7. Accessory Gearbox Carbon Seals Installation.
A. Install mating seal ring as follows:
NOTE
Tool numbers 1C8182P07 and P08 are used at starter pad. Tool numbers
1C8182P14 and P15 are used at fuel pump pad and auxiliary accessory
drive pad.
(1) Using petrolatum, lubricate new preformed packing and install into mating seal
ring packing groove (figure 2).
CAUTION
Use care to avoid damaging packing during installation of mating
seal ring.
(2) Using seal ring installation pliers from fixture set, 1C8182, install mating seal ring
onto shaft. Ensure tangs of mating seal ring fully engage slots of bearing inner
race. Following installation of mating seal ring, take drop from gearbox face to aft
surface of mating seal ring. Compare to reading taken during removal.
B. Install new carbon seal as follows:
(1) Using petrolatum, lubricate new preformed packing and install into gearbox
housing bore (figure 1).
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WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated
or prolonged contact. Use in a well-ventilated area.
CAUTION
During handling, protect mating surfaces of mating seal ring and
carbon seal from contamination, including fingerprints. The seal
ring and carbon seal are matched parts; do not interchange.
(2) Lubricate internal elements of carbon seal with lubricating oil. Depress and
release carbon seal slowly several times to ensure seal operates smoothly.
(3) Apply light coat of lubricating oil onto carbon seal face, seal housing outside
diameter, and face of mating seal ring.
(4) Install locally fabricated guide pins into gearbox housing inserts to align seal tang
boltholes with inserts during installation.
CAUTION
• Before installation, ensure carbon seal is clean and free of
debris. Contamination may cause carbon seal failure.
• Take care not to disturb or damage packing during installation.
• To prevent damage to carbon seal, ensure the tangs of the seal
ring fully engage slots of the bearing inner race.
(5) Install carbon seal over guide pins and carefully push into housing until seal
flange is fully seated against housing face. Remove guide pins.
NOTE
Perform step (6) only if starter pad carbon seal was replaced.
(6) Install seal retainer at starter pad.
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CAUTION
Ensure prebent tabs of keywasher contact CCW against bearing
housing ear with zero clearance. Do not use force or distort prebent
tab of keywasher into position.
(7) Install new keywashers and bolts.
CAUTION
Do not loosen bolt to position a flat on the bolthead adjacent to the tab.
(8) Tighten bolts to 33-37 lb in. (3.8-4.1 N·m) of torque. Determine if flat on bolthead
is adjacent to tab of keywasher. If necessary, continue to tighten bolt to a maxi-
mum of 40 lb in. (4.6 N·m) of torque until flat on bolthead is adjacent to tab. Bend
tab into position. See figure 3.
(9) Install new gasket, cover, and coupling clamp or bolts and washers, as applicable.
Tighten coupling clamp to 100-130 lb in. (11.3-14.6 N·m) of torque. Tighten bolts
to 190-230 lb in. (21.5-25.9 N·m) of torque.
3
Figure 3. Typical Keywasher Installation
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WORK PACKAGE
TECHNICAL PROCEDURES
GAS TURBINE IN ENCLOSURE REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 20
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 20 ...... 3
Alphabetical Index
Subject Page
Gas Turbine Installation into Enclosure...................................................................................... 14
Gas Turbine Removal from Enclosure........................................................................................ 6
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1. Introduction.
A. This work package contains instructions for removing or installing the gas turbine in an
enclosure.
B. Disconnect and connect electrical leads and connecting tubes on the gas turbine per
SWP 1913 01, SWP 1913 02, SWP 1913 03, and SWP 1913 04.
NOTE
Testing has demonstrated that failure to complete the following purge
procedure will result in residual fuel within the gas turbine and fuel
supply system and the engine cannot be declared Non-HAZMAT for
shipping. Similarly, testing shows that, if the procedure is completed,
the engine will be free of fuel and can be declared Non-HAZMAT.
C. Normal Shutdown and Cooldown. If the gas turbine including fuel system is to be removed
from the enclosure in preparation for shipment by ground or air, complete the following fuel
system drain and purge procedure. Fuel system removal prior to shipment does not require
the purge procedure.
(1) While the engine is still in the enclosure, disconnect all fuel manifolds at the package
supply interface.
WARNING
Lubricating oil, MIL-L-6081, is toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
(a) Liquid Fuel - If present, should be drained into a container or fuel drain tank when
the fittings are opened. Any locations such as flow splitter, pressurization valve or
flow divider should also be isolated and drained. As an alternative to ventilating, the
liquid fuel system can be filled with MIL-L-6081, Grade 1010 slush oil. This alter-
native is preferred if the engine is to be stored for extended periods before or after
service.
(b) Gas Fuel - Open the fuel manifold fittings and allow them to ventilate into the
enclosure.
(2) Using the Human Machine Interface (HMI), start the enclosure ventilation fan(s).
(3) Initiate a Dry Crank (no fuel supply) using the HMI and allow the engine to ramp to
2200 rpm HP rotor speed for 10 minutes. This will ventilate any remaining fuel or vapor
into the enclosure using compressor discharge air.
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(4) For DLE units, all staging valves should be normally open. If there are any normally
closed valves in the system the HMI should be used to open them.
(5) After 10-minute purge, stop dry crank.
(6) Stop ventilation fan(s).
(7) Complete gas turbine removal.
D. Emergency Shutdown or Engine Failure. If the gas turbine including fuel system is to be
removed from the enclosure in preparation for shipment by ground or air, complete the fol-
lowing fuel system drain and purge procedure. Fuel system removal prior to shipment does
not require the purge procedure.
(1) While the engine is still in the enclosure, disconnect all fuel manifolds at the package
supply interface as well as at all nozzles or premixers.
(2) Using the HMI, start the enclosure ventilation fan(s).
(3) Drain and blow out all fuel lines.
WARNING
Lubricating oil, MIL-L-6081, is toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
(a) Liquid Fuel - If present, should be drained into an approved container or the fuel
drain tank when the fittings are opened. Any locations such as flow splitter, pressur-
ization valve or flow divider should also be isolated and drained. As an alternative to
ventilating, the liquid fuel system can be filled with MIL-L-6081, Grade 1010 slush
oil. This alternative is preferred if the engine is to be stored for extended periods
before or after service.
(b) Open the combustor case drain fitting and drain any residual fuel into an approved
container or the fuel drain tank.
WARNING
When using compressed air for cleaning, cooling, or drying, do not
exceed 30 psig (207 Kpa). Wear eye protection and do not direct
compressed air at self or others.
(c) After all fuel is drained, blow out each of the lines, hoses and connections with shop
air.
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(d) Gas Fuel - Open the fuel manifold fittings and blow out each of the lines, hoses and
connections with shop air.
(4) Stop ventilation fan(s).
(5) Reconnect fuel nozzles or premixers.
(6) Complete gas turbine removal.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Inlet Guide Vane (VIGV) Actuator Replacement with SWP 1112 01
Fixed Link
Front Frame Module External Tubing, Harnesses, and Clamp- SWP 1913 01
ing
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Low Pressure Turbine (LPT) Module External Tubing, Har- SWP 1913 03
nesses, and Clamping
Engine Assembly External Tubing, Harnesses, and Clamping SWP 1913 04
Gas Turbine Maintenance Dolly Removal and Installation WP 3012 00
Gas Turbine/Support Pedestal Removal and Installation WP 3013 00
Gas Turbine in Shipping Container Replacement WP 3014 00
Steam/Fuel Manifold Shipping Bracket Fixture Replacement WP 3015 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Fixture Assembly, Horizontal Lift 1C9625G01
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4. Consumable Material.
Nomenclature Specification
Marking Pen Sharpie T.E.C.
(Black or Blue)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Packager-supplied gaskets are required to perform the tasks described in this work package.
(Reference packager's manual.)
Nomenclature Part No. Qty
Ignitor Plug (Blank off) L44539P01 1
Washer 9397M22P02 1
Piston Ring, Outer L45063P16 1
Piston Ring, Outer L45063P13 ALT
Piston Ring, Inner L47833P01 1
Piston Ring, Inner L47833P02 ALT
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6. Gas Turbine Removal from Enclosure.
See figure 1.
A. If previously installed on gas turbine with VIGV assembly, remove fixed links and install
VIGV actuators as follows:
(1) Remove fixed link per SWP 1112 01. Secure fixed link to gas turbine for return with gas
turbine.
(2) Install VIGV actuators per SWP 1112 01.
CAUTION
Ensure all electrical, fuel, oil, and air supplies are shut off before
disconnecting customer interfaces. Failure to comply may result in
part damage.
B. Disconnect inlet, exhaust, bypass air, and drive interfaces as follows:
(1) Disconnect inlet system from variable inlet guide vane (VIGV) case or inlet frame
assembly per packager's manual.
(2) Disconnect exhaust system per packager's manual.
(3) Disconnect bypass air collection system per packager's manual.
(4) If same gas turbine will be installed, matchmark drive adapter and shaft using
marking pen.
(5) Disconnect forward and aft drive adapters per packager's manual.
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Figure 1. Gas Turbine Mount Locations
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C. Disconnect customer electrical interfaces as follows:
WARNING
Before you disconnect the ignition leads, make sure the ignition
system was off for more than 2 minutes. The ignition system could
be charged with high voltage that can cause death.
NOTE
Some engines may have only one ignition plug at 3:00 o'clock position
and a blank off plug at 5:00 o'clock position.
(1) Disconnect igniter cables from igniters as follows:
CAUTION
• Ensure igniter adapter is restrained when loosening or tightening
coupling nut. Failure to comply may result in part damage.
• Igniter plug may fall out when ignition cable is disconnected.
(a) Remove safety wire. Disconnect ignition cables from igniter plug adapters.
Momentarily ground ignition cable to remove any residual electrical charge.
(b) Install igniter plug cover or covers. Tighten covers to 23.0-27.0 lb ft
(31.2-36.6 N·m) of torque.
(c) Remove nut, bolt, and clamps that secure ignition cables onto gas turbine bracket.
(2) Disconnect flame sensor integral leads from packager's junction box per packager's
manual.
(3) If required, disconnect starter speed switch connector from pneumatic starter per
packager's manual.
(4) Disconnect customer electrical cables as follows:
(a) Using marking pen, matchmark customer electrical cable connections at electrical
interface panels.
(b) Remove bolts, washers, and clamps that secure customer electrical cables onto
electrical interface panels.
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WARNING
Circuits shall be open (off) and capacitors discharged to ground
before proceeding. Electricity causes shock, burns, and death.
(c) Disconnect customer electrical cable connectors from electrical interface panels per
packager's manual.
D. Disconnect remaining customer hydraulic, pneumatic, lube oil, fuel, and vent/drain interfaces
per SWP 1913 01, SWP 1913 02, SWP 1913 03, and SWP 1913 04.
E. Install steam/fuel manifold shipping bracket fixture assembly per WP 3015 00.
F. Remove bolts that secure fuel and steam manifold mounts onto packager's stanchions per
packager's manual.
G. Remove gas turbine from enclosure as follows:
(1) Attach hoist of sufficient lifting capacity to horizontal lift fixture, 1C9625, or equivalent.
See figure 2.
WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they
can cause an injury or death.
(2) Raise horizontal lift fixture, 1C9625, to working height. Level fixture by adjusting
trolley. Record center of gravity (CG) measurement.
(3) Position horizontal lift fixture, 1C9625, over gas turbine. Using quick-release pins,
secure lift fixture clevis, 1C9625P09, onto rear mounts on turbine rear frame.
(4) Position lift fixture front frame adapter onto front frame forward lift point. Install
quick-release pin.
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Figure 2. Horizontal Lift Fixture, 1C9625 (Sheet 1 of 2)
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Figure 2. Horizontal Lift Fixture, 1C9625 (Sheet 2 of 2)
CAUTION
Ensure lift fixture trolley is set to 30.1 inches (764.5 mm) for engines
with VIGV installed, and 31.8 inches (807.7 mm) for engines with
inlet frame installed. Incorrect positioning may cause lift fixture/gas
turbine damage.
(5) Position lift fixture trolley to 30.1 inches (764.5 mm) for engines with VIGV installed,
and 31.8 inches (807.7 mm) for engines with inlet frame installed. Slowly apply small
amount of lifting force on hoist. Ensure lift fixture is properly attached to gas turbine.
WARNING
Ensure hoist and lift fixture are aligned prior to removing rear
mount pins. Failure to comply may result in gas turbine shifting,
causing serious injury.
(6) Remove trunnion attachments and aft mount attachment per packager's manual.
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WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they
can cause an injury or death.
CAUTION
Ensure rear mount links do not drop onto gas turbine components
while gas turbine is raised from enclosure. Gas turbine damage may
result.
(7) Lift gas turbine and maneuver to remove from enclosure.
(8) Install gas turbine into applicable support equipment per WP 3012 00, WP 3013 00, or
WP 3014 00.
(9) Install inlet, exhaust, and air collector covers.
H. Using bright light, visually inspect inner and outer piston rings for wear and cracks (figure 3).
If rings are worn or cracked, replace rings.
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Figure 3. Gas Turbine Exhaust Duct Interface
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7. Gas Turbine Installation into Enclosure.
A. If lease engine is being installed with dual ignition system and site is set up for single
ignition system, it will be required that a plug and washer be installed in the 5:00 o'clock
igniter plug position. See Illustrated Parts Breakdown, GEK 105060.
CAUTION
Do not operate engine with ignitor plug cover installed in
place of L44539P01 blank off plug.
NOTE
The fixed IGV configuration can be identified as follows:
• Zero Degree - Has a light green primer on inlet guide vane frame
outer surface and gray urethane paint on flowpath surfaces.
• Negative Five Degree - Pre CID 464632 has a light green primer on
the inlet guide vane frame outer surface and tan/beige urethane
paint on the flowpath surfaces. Post CID 464632 has gray urethane
paint on outer surface and on flowpath surfaces of inlet guide vane
frame.
B. If replacement gas turbine, equipped with VIGV actuator, is replacing gas turbine with
fixed link, replace VIGV actuators with fixed links per SWP 1112 01.
C. Verify the rear drive adapter or aft seal spacer, whichever is applicable, is installed. Refer to
WP 2711 00.
D. Install gas turbine in enclosure as follows:
WARNING
Ensure hoist and lift fixture are aligned prior to removing rear
mount pins. Failure to comply may result in gas turbine shifting,
causing serious injury.
(1) Position aft mount links outboard.
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WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they
can cause an injury or death.
CAUTION
Ensure rear mount links do not drop onto gas turbine components
while gas turbine is raised from enclosure. Gas turbine damage may
result.
(2) Lower gas turbine into enclosure and align aft clevis mounts with mount links.
(3) Install trunnion pins into trunnion support stanchions per packager's manual.
(4) Install trunnion washers and nuts onto gas turbine trunnions. Tighten nuts per packager's
manual.
(5) Install mount bolt and nut through aft left mount link and gas turbine mount. Tighten nut
per packager's manual.
(6) Install mount bolt and nut through aft center mount and gas turbine mount. Tighten nut
per packager's manual.
(7) Adjust aft right mount link so mount bolt can be inserted freely. Install mount bolt and
nut through aft right mount link and gas turbine mount. Tighten nut per packager's
manual.
(8) Tighten aft right mount link jamnut per packager's manual.
(9) Slowly release tension on hoist.
WARNING
Ensure lift fixture is located at the center of gravity before discon-
necting from gas turbine. Failure to comply may result in gas tur-
bine damage or serious injury.
(10) Position lift fixture trolley at CG. Slowly apply lifting force to allow lift fixture pins to
rotate freely. See figure 2.
WARNING
Always use approved equipment and procedures to lift parts. Stay
out from below loads. If the parts accidentally move or fall, they
can cause an injury or death.
(11) Remove two turbine rear frame lift fixture quick-release pins. Remove forward lift point
quick-release pin. Raise lift fixture clear of gas turbine.
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E. Connect inlet, exhaust, bypass air, and drive interfaces as follows:
(1) If installed, remove inlet, exhaust, and air collector covers.
(2) Connect forward and aft drive adapters per packager's manual.
(3) Connect exhaust system per packager's manual.
(4) Connect inlet system to VIGV case or inlet frame assembly per packager's manual.
(5) Connect bypass air collection system per packager's manual.
F. Connect customer electrical interfaces as follows:
NOTE
• LM6000 PC gas turbines, serial numbers 191-100 through 191-177
and 191-179, were delivered with a speed sensor mounted on the LPC
casing (this sensor is sometimes referred to as the XN2 speed sensor).
When installing an LM6000 PC engine without an XN2 speed sensor
(SN 191-178 and 191-180 and up), the XN2 harness connector should
be protected with tape or other suitable means, and an adjustment
must be made to the control system. Control system tunable switch
N2SELSW (contact packager or control supplier to confirm this
parameter name) must be set to False to run with the LPT (XNSD)
sensors only. When subsequently installing a gas turbine with an XN2
sensor, the software switch should be reset to its original setting
(True).
• When installing an LM6000 PC engine that has an XN2 sensor into
a site which does not have cabling to accept this speed input, the
sensor lead should be secured with a nylon wire tie or appropriate
means to prevent wearing or chafing of the sensor lead. There is no
need in this case to change any software settings.
(1) Connect customer electrical cables as follows:
WARNING
Circuits shall be open (off) and capacitors discharged to ground
before proceeding. Electricity causes shock, burns, and death.
(a) Connect customer electrical cables to electrical interface panels.
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(b) Using bolts, washers, and clamps, secure customer electrical cables onto electrical
interface panels. Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
(2) Connect igniter cables to igniters as follows:
WARNING
Before you disconnect the ignition leads, make sure the ignition
system was off for more than 2 minutes. The ignition system could
be charged with high voltage that can cause death.
CAUTION
Igniter plug may fall out when ignition cable is disconnected or
igniter plug cover is removed.
(a) Remove igniter plug covers at 3:00 o'clock position, and if installed, at 5:00 o'clock
position.
(b) Install ignition cables over igniter plug adapters. Tighten coupling nuts to
23-27 lb ft (31-37 N·m) of torque. Safety-wire coupling nut.
(3) Connect flame sensor integral lead to packager's junction box per packager's manual.
CAUTION
Do not operate engine with ignitor plug cover installed in place of
ignition plug or blank off plug.
NOTE
Some engines may have only one ignition system (3:00 o'clock position)
and a blank off plug will then be required at the 5:00 o'clock position.
(4) If required, connect starter speed switch connector to pneumatic starter per packager's
manual.
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CAUTION
Position hydraulic, pneumatic, lube oil, fuel, water, steam, and
vent/drain interfaces to avoid interference with engine components
that could result in premature failure.
G. Check for misalignment and interference between engine and package interfaces. Adjust and
correct as required.
H. Connect remaining customer hydraulic, pneumatic, lube oil, fuel, and vent/drain interfaces
per SWP 1913 01, SWP 1913 02, SWP 1913 03, and SWP 1913 04.
NOTE
Misalignment between the fuel and steam manifolds, and the packager's
stanchions may indicate that the packager's supporting stanchions are
located incorrectly.
I. Install bolts that secure fuel and steam manifolds to packager's stanchions. Tighten bolts to
100-130 lb in. (11.3-14.7 N·m) of torque.
J. Remove steam/fuel manifold shipping bracket fixture assembly per WP 3015 00.
NOTE
Contact your control vendor for proper configuration for engine con-
trols not listed in table 1 or table 2.
K. Ensure the control software is correctly configured for the engine IGV configuration (refer to
table 1 or table 2) if engine is installed with a different IGV configuration than on the engine
removed.
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Table 1. Salem Control
Engine to Install 0 Degree FIGV -5 Degree FIGV VIGV
Engine
Removed
0 Degree FIGV Mark V all versions, N/A. Mark V all versions,
Software and hardware do set control software
not support -5 Degree FIGV. NOVIGVSW to true.
Mark VI - Version S4 and Mark VI - Version S4 and
lower, N/A. Software does lower, set control software
not support -5 Degree FIGV. NOVIGVSW to true.
Mark VI and VIe-Version Mark VI and VIe-Version
S5 and higher required, S5 and higher, set control
set control software software IGVCFGSW to 2
IGVCFGSW to 3
-5 Degree FIGV Mark V all versions, N/A. Mark V all versions, N/A.
Software and hardware do Software and hardware do
not support -5 Degree not support -5 Degree
FIGV. FIGV.
Mark VI - Version S4 and Mark VI - Version S4 and
lower, N/A. Software does lower, N/A. Software does
not support -5 Degree not support -5 Degree
FIGV. FIGV.
Mark VI and VIe-Version Mark VI and VIe - Version
S5 and higher, set control S5 and higher, set control
software IGVCFGSW to 2 software IGVCFGSW to 3
VIGV Mark V all versions, Mark V all versions, N/A.
set control software Software and hardware do
NOVIGVSW to true. not support -5 Degree FIGV.
Mark VI - Version S4 and Mark VI - Version S4 and
lower, set control soft- lower, N/A. Software does
ware NOVIGVSW to true. not support -5 Degree FIGV.
Mark VI and VIe-Version Mark VI and VIe-Version
S5 and higher, set control S5 and higher required,
software IGVCFGSW to 2 set control software
IGVCFGSW to 3
Note: Any Mark V can get
alarm on VIGV on differ-
ences. Reference Salem
instructions.
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Table 2. Woodward Control
Engine to Install 0 Degree FIGV -5 Degree FIGV VIGV
Engine
Removed
0 Degree FIGV Version S4 and lower, N/A. Version S4 and lower,
Software does not support set control software
-5 Degree. NOVIGVSW to true.
Version S5 and higher, Version S5 and higher,
set control software set control software
IGVCFGSW to 3 IGVCFGSW to 2
-5 Degree FIGV Version S4 and lower, Version S4 and lower, N/A.
N/A. Software does not Software does not support
support -5 Degree. -5 Degree.
Version S5 and higher, Version S5 and higher,
set control software set control software
IGVCFGSW to 2 IGVCFGSW to 3
VIGV Version S4 and lower, Version S4 and lower, N/A.
set control software Software does not support
NOVIGVSW to true. -5 Degree.
Version S5 and higher, Version S5 and higher,
set control software set control software
IGVCFGSW to 2 IGVCFGSW to 3
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WORK PACKAGE
TECHNICAL PROCEDURES
PRESERVATION/DEPRESERVATION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 34
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 34 ...... 3
Alphabetical Index
Subject Page
Definitions................................................................................................................................... 4
Engine Depreservation................................................................................................................ 33
Installed Engine for Greater than 30 Days Preservation............................................................. 26
Installed Engine for up to 30 Days Preservation......................................................................... 4
Noninstalled Engine for Greater than 30 Days Preservation ...................................................... 30
Noninstalled Engine for up to 30 Days Preservation.................................................................. 29
Oil Wetting LM6000 Bearings (Alternate Procedure 1) ............................................................. 14
Oil Wetting LM6000 Bearings (Alternate Procedure 2) ............................................................. 25
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1. Introduction.
This work package contains instructions for preservation/depreservation of the engine.
2. Reference Material.
Title Number
Deleted
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Pressurizer, Hydraulic Unit 1C3569G2
Hydraulic Actuator Unit 1C3569G3
Spline Adapter, Manual or Front Drive Pad 1C8208G02
Drive Motor, Electric (115 VAC 50/60 and 2C14764G05
400 Hz, 28 VDC)
Drive Motor, Electric (220 VAC 50 Hz and 2C14764G06
28 VDC)
Actuator, VGV Hydraulic (Alternate to 2C6395G05
1C3569G2)
Drive Motor, Pneumatic 18932
Reducer AN919-6
Reducer AN919-10
Reducer MS51525B6-8S
Reducer MS51525B8-10S
Reducer MS51525B8-12S
Union MS51525B8S
Cap MS51532B6S
Cap MS51532B10S
Lubricating Stand Local Purchase
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4. Consumable Material.
Nomenclature Specification
Barrier Paper (Kraft) Grade A, Type II, Class II
Desiccant MIL-P-116
Fuel System Preservation Oil MIL-L-6081, Grade 1010
Lubricating Oil MIL-PRF-23699F (C/I)
Rust Preventive Concentrate GE Spec D50TF6 or
Brayco 599
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Gasket, Seal J219P05A 2
Packing, Preformed 140100-110 2
Packing, Preformed J221P014 1
Packing, Preformed J221P134 1
Packing, Preformed J221P904 2
Packing, Preformed J221P906 2
Packing, Preformed J221P908 3
Packing, Preformed M83248/1-912 6
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6. Definitions.
For purposes of this work package, the following definitions apply:
A. Installed engine - An engine installed in the enclosure.
B. Noninstalled engine - An engine installed in a maintenance dolly or pedestals, or an
engine installed in a shipping container.
7. Installed Engine for up to 30 Days Preservation.
CAUTION
• Ensure driven equipment is prelubricated or drive shaft is dis-
connected prior to motoring engine. Failure to comply may
result in damage to driven equipment or lack of low pressure
rotor rotation and subsequent insufficient bearing lubrication.
• Do not exceed starter duty cycle when motoring. Hydraulic
starter has no duty cycle limitations except oil temperature shall
be maintained below 140°F (60°C). Pneumatic starter duty cycle
follows:
5 minutes on, 2 minutes off,
5 minutes on, 18 minutes off,
or
10 minutes on, 20 minutes off.
A. Inspect inlet, exhaust, and variable bleed valve (VBV) discharge.
B. Remove moisture barrier paper, covers, and plugs from engine.
C. Oil wet bearings using one of the following three procedures:
(1) Oil wet bearings per paragraphs 7.D through 7.I
(2) Oil wet bearings per paragraph 8.
(3) Oil wet bearings per paragraph 9
2
1
D. Connect lubricating stand as follows:
(1) Install locally manufactured blankoff plates (figure 1) using existing gaskets,
bolts, and washers onto ports L1, L2, and L3. See figure 2. Tighten bolts on port
L1 to 420-510 lb in. (47.4-57.6 N·m) of torque. Tighten bolts on port L2 to
250-320 lb in. (28.2-36.1 N·m) of torque. Tighten bolts on port L3 to
160-210 lb in. (18.0-23.7 N·m) of torque.
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Figure 1. Locally Manufactured Blankoff Plates
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Figure 2. Lubricating Oil Manifold Ports (Sheet 1 of 2)
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Figure 2. Lubricating Oil Manifold Ports (Sheet 2 of 2)
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(2) Install cap, PN MS51532B6S, onto scavenge discharge pressure port L5 fitting.
(3) Remove protective cap from supply pressure port L4 fitting.
(4) Remove fitting from supply pressure port L4. Discard preformed packing.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(5) Lubricate new preformed packing, PN J221P906, with lubricating oil and install
onto reducer, PN MS51525B6-8S. Install reducer into supply pressure port L4.
Tighten reducer to 180-200 lb in. (20.3-22.5 N·m) of torque.
(6) Connect lubricating stand supply hose onto reducer at supply pressure port L4.
Tighten coupling nut to 450-550 lb in. (50.8-62.1 N·m) of torque.
(7) Remove drain plug from forward side of accessory gearbox.
(8) Lubricate preformed packing, PN J221P908, with lubricating oil and install onto
union, PN MS51525B8S. Install union into accessory gearbox drain port. Tighten
union to 270-300 lb in. (30.5-33.8 N·m) of torque.
(9) Connect lubricating stand scavenge hose onto union on accessory gearbox drain
port. Tighten coupling nut to 450-550 lb in. (50.8-62.1 N·m) of torque.
(10) )Remove transfer gearbox (TGB), B- and C-sump scavenge inlet screen plugs
from lube and scavenge pump. Discard preformed packings.
(11) Lubricate preformed packings, PN M83248/1-912, with lubricating oil and install
onto reducers, PN MS51525B8-12S. Install reducers into TGB, B- and C-sump
scavenge ports. Tighten reducers to 45-50 lb ft (61-68 N·m) of torque.
(12) Connect lubricating stand scavenge lines onto TGB, B- and C-sump scavenge port
reducers. Tighten coupling nuts to 450-550 lb in. (50.8-62.1 N·m) of torque.
(13) Disconnect D-sump scavenge hose from D-sump scavenge in port fitting. Install
cap, PN MS51532B10S, onto fitting. Tighten cap finger-tight.
(14) Install reducer, PN MS51525B8-10S, onto D-sump scavenge hose. Tighten
reducer to 650-770 lb in. (73.4-86.9 N·m) of torque.
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(15) Connect lubricating stand scavenge hose onto reducer on D-sump scavenge hose.
Tighten coupling nut to 450-550 lb in. (50.8-62.1 N·m) of torque.
(16) Disconnect E-sump scavenge hose from E-sump scavenge in port fitting. Install
cap, PN MS5132B10S, onto fitting. Tighten cap finger-tight.
(17) Install reducer, PN MS51525B8-10S onto E-sump scavenge hose. Tighten
reducer to 650-770 lb in. (73.4-86.9 N·m) of torque.
(18) Connect lubricating stand scavenge hose onto reducer on E-sump scavenge hose.
Tighten coupling nut to 450-550 lb in. (50.8-62.1 N·m) of torque.
E. Install spline adapter and electric/pneumatic drive motor as follows:
(1) Remove nuts and washers securing forward drive pad cover to front of accessory
gearbox. Remove cover. Discard preformed packing.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(2) Lubricate spline adapter, 1C8208, with lubricating oil. Install spline adapter into
spline adapter forward drive spline and secure with washers and nuts. Tighten
nuts to 100-130 lb in. (11.2-14.6 N·m) of torque.
(3) Install electric drive motor, 2C14764, or pneumatic drive motor, 18932, onto
forward drive pad aligning square drive with spline adapter. Secure with washers
and bolts. Tighten bolts to 420-510 lb in. (47.4-57.6 N·m) of torque.
(4) Connect drive motor to applicable power source.
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F. Oil-wet engine bearings as follows:
WARNING
Rust preventive concentrate, Brayco 599: Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
NOTE
The use of rust preventive concentrate, Brayco 599, is optional if
preservation period is less than 15 days.
(1) Add 5 percent (by volume) of rust preventive concentrate, Brayco 599, to
lubricating stand oil tank.
CAUTION
Ensure lubricating stand scavenge lines show visible flow through
viewing windows. If flow is not observed, stop lubricating stand
supply and scavenge pumps and check fittings for leaks. Failure to
comply may result in overflow of oil sumps.
(2) Start lubricating stand supply and scavenge pumps. See figure 3 Regulate supply
pressure to 5-10 psi (34-69 kPa). Lube oil temperature shall be maintained
between 60 and 100°F (15.6 to 37.8°C).
WARNING
Use thermal gloves when you move or touch hot or cold parts.
Hot or cold parts can cause injury.
CAUTION
Failure to rotate low pressure rotor will result in insufficient
lubrication of no. 1, 2, 6, and 7 bearings.
(3) Rotate high pressure turbine (HPT) rotor, using electric/pneumatic drive motor, in
forward direction a minimum of two revolutions (approximately 12-15 minutes)
at maximum RPM. Rotate low pressure turbine (LPT) rotor, using driven
equipment jacking gear (if installed), a minimum of two revolutions. If jacking
gear is not installed, disconnect coupling shaft to driven equipment and rotate LPT
rotor by pulling stage 5 LPT blades minimum of two revolutions.
(4) Stop lubricating stand supply pump. Run scavenge pump until no oil flow is
visible in scavenge line viewing windows. Stop scavenge pump.
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Figure 3. Typical Lubricating Stand
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G. Disconnect lubricating stand as follows:
(1) Disconnect lubricating stand supply line from supply pressure port L4.
(2) Remove reducer from supply pressure port L4.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(3) Lubricate new preformed packing with lubricating oil and install onto
fitting. Install fitting in supply pressure port L4. Tighten fitting to 180-200 lb in.
(20.3-22.5 N·m) of torque.
(4) Disconnect lubricating stand scavenge lines from TGB, B-, and C-sump scavenge
inlet port fittings. Remove fittings.
(5) Lubricate three preformed packings with lubricating oil and install on TGB,
B- and C-sump scavenge inlet screen plugs.
(6) Install inlet screen plugs into TGB, B-, and C-sump scavenge inlet ports. Tighten
plugs to 540-600 lb in. (61.0-67.7 N·m) of torque.
(7) Remove cap from main scavenge discharge tube. Install pump scavenge
discharge hose onto main scavenge discharge tube. Tighten coupling nut to
133-150 lb ft (180-203 N·m) of torque.
(8) Disconnect lubricating stand accessory gearbox scavenge hose. Remove
accessory gear-box scavenge hose adapter.
(9) Lubricate preformed packing with lubricating oil and install onto accessory
gearbox drain plug.
(10) Install accessory gearbox drain plug. Tighten plug to 270-300 lb in.
(30.5-33.8 N·m) of torque. Safety-wire plug.
(11) Remove caps from D- and E-sump scavenge fittings.
(12) Disconnect lubricating stand scavenge hose from reducer on D-sump scavenge
hose. Remove reducer from D-sump scavenge hose.
(13) Connect D-sump scavenge hose onto D-sump scavenge fitting. Tighten coupling
nut to 650-770 lb in. (73.4-86.9 N·m) of torque.
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(14) Disconnect lubricating stand scavenge hose from reducer on E-sump scavenge
hose. Remove reducer from E-sump scavenge hose.
(15) Connect E-sump scavenge hose onto E-sump scavenge fitting. Tighten coupling
nut to 650-770 lb in. (73.4-86.9 N·m) of torque.
(16) Remove cap from scavenge discharge pressure port L5.
H. Remove electric/pneumatic drive motor and spline adapter as follows:
WARNING
Use extreme care when working with electricity. Electricity
causes shock, burns, and death.
(1) Disconnect drive motor from power source.
(2) Remove bolts and washers that secure drive motor onto accessory gearbox.
Remove drive motor.
(3) Remove nuts, washers, and spline adapter, 1C8208, from accessory gearbox.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(4) Lubricate preformed packing with lubricating oil and install into preformed
packing groove on cover.
(5) Install forward drive pad cover onto accessory gearbox forward drive pad. Secure
with washers and nuts. Tighten nuts to 100-130 lb in. (11.2-14.6 N·m) of torque.
I. Cover or plug all engine openings and unattached fittings. Cover inlet, exhaust, and
VBV openings using moisture barrier paper, if possible.
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8. Oil Wetting LM6000 Bearings (Alternate Procedure 1).
A. Oil wet gearbox bearings as follows:
WARNING
• Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust venti-
lation - if not available, use an approved respirator.
• Rust preventive concentrate, Brayco 599: Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
NOTE
The use of rust preventive concentrate, Brayco 599, is optional if
preservation period is less than 15 days.
(1) Thoroughly mix 6 quarts (6 liters) of lubricating oil with 290 cc of Brayco 599
preventive to obtain 5 percent mixture.
(2) Remove oil from reservoir of hydraulic unit pressurizer, 1C3569. Pour oil/Brayco
mixture into unit pressurizer reservoir.
(3) Remove tube-end reducer, nut, -6/-4 reducer, and cap from head-end hose swivel
of unit pressurizer. Head-end and rod-end lines are identified with tag.
(4) Move unit pressurizer selector valve to head-end position, open supply valve on
head-end line, and close supply valve on rod-end.
(5) Locate gearbox drain plug (figure 4) and place clean container under drain.
Remove drain plug (some packages may have a starter clutch drain attached).
Dispose of drained oil and return container under drain.
(6) Remove four nuts and washers from accessory gearbox manual drive pad cover
plate (figure 5). Remove cover plate.
(7) Insert 3/4 -inch by 12-inch-drive extension into manual drive pad and attach
ratchet.
(8) Remove oil supply manifold as follows (figure 6):
(a) Disconnect gearbox lube oil supply tube.
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Figure 4. Gearbox
(b) Disconnect A-sump oil supply tube.
(c) Disconnect B-, C-, D-, and E-sump tubes.
6
5
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(d) Remove electrical connector from lube oil supply resistance temperature
detector (RTD).
(e) Disconnect other packager connections, as required.
(f) Remove bolts and washers connecting oil supply manifold onto oil manifold.
Remove manifold and store in clean container.
(g) Cap or tape all openings to avoid lube system contamination.
(9) Locate gearbox lube oil supply tube and install reducer. Connect unit pressurizer
head-end line onto reducer.
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Figure 5. Front Frame and Gearbox (Sheet 1 of 2)
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Figure 5. Front Frame and Gearbox (Sheet 2 of 2)
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Figure 6. Oil Supply Manifold
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CAUTION
During operation of hydraulic unit pressurizer, 1C3569, observe
head-end pressure gage to verify pressure buildup does not exceed
100 psi (689.4 kPa) or damage to gearbox seals may result.
NOTE
• Pump handle of hydraulic unit pressurizer, 1C3569, shall be
operated rapidly through the full piston stroke to ensure the
proper amount of oil/preservative mixture is supplied to the
sump.
• Core RPM can be determined by observing rotation of ratchet
drive. A ratchet drive speed of 7 RPM equals core speed of
10 RPM.
(10) Use ratchet in manual drive pad to rotate core 5-10 RPM clockwise (aft looking
forward) while operating unit pressurizer, 1C3569, pump handle (maintain
20 psig [137.8 kPa] minimum pressure). Rotate core and activate pump handle
for 2 minutes.
(11) Remove hydraulic unit pressurizer, 1C3569, head-end line from gearbox oil
supply line. Cap or tape gearbox lube oil supply tube to avoid lube system
contamination.
WARNING
• Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do
not inhale, ingest, or let this material touch you. Irritant. Per-
sonal protective equipment required. Use mechanical exhaust
ventilation - if not available, use an approved respirator.
• Rust preventive concentrate, Brayco 599: Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(12) Allow oil/preservation mixture to drain from gearbox into container. If clean,
pour mixture from container into hydraulic unit pressurizer, 1C3569, reservoir
and replace container under open gearbox drain. If reservoir does not contain
approximately 6 quarts (6 liters) (reservoir capacity), mix an additional 5 percent
mixture and fill reservoir.
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B. Oil wet A-sump bearings as follows:
(1) Locate A-sump oil supply tube (figure 6) and install reducer. Connect hydraulic
unit pressurizer, 1C3569, head-end line to reducer.
CAUTION
During operation of hydraulic unit pressurizer, 1C3569, observe
head-end pressure gage to verify pressure buildup does not exceed
100 psi (689.4 kPa) or damage to gearbox seals may result.
NOTE
Pump handle of hydraulic unit pressurizer, 1C3569, shall be operated
rapidly through the full piston stroke to ensure the proper amount of
oil/preservative mixture is supplied to the sump.
(2) Use ratchet in manual drive pad to rotate core 5-10 RPM clockwise (aft looking
forward). Simultaneously rotate low pressure rotor by hand using rear drive
adapter (the gas turbine shall be disconnected from the electrical generator or
drive equipment). Rotate both rotors while operating hydraulic unit pressurizer
pump, 1C3569, handle (maintain 20 psig [137.8 kPa] minimum pressure). Rotate
rotors and activate pump handle for 2 minutes.
(3) Remove hydraulic unit pressurizer, 1C3569, head-end line from A-sump oil
supply tube. Cap or tape A-sump oil supply tube to avoid lube system
contamination.
(4) Install locking ring, preformed packing and drain plug into gearbox. Tighten plug
to 270-300 lb in. (30.5-33.8 N·m) of torque.
(5) Inspect oil/Brayco 599 mixture. If serviceable, pour mixture from container into
hydraulic unit pressurizer, 1C3569, reservoir. If reservoir does not contain approx-
imately 6 quarts (6 liters) (reservoir capacity), mix an additional 5 percent
oil/Brayco mixture and fill reservoir.
(6) Attach oil supply manifold as follows (figure 6):
(a) Install oil supply manifold onto oil manifold with three washers and bolts.
Tighten bolts to 55-70 lb in. (6.2-7.9 N·m) of torque.
(b) Connect gearbox lube oil supply tube and preformed packing. Tighten fitting
to 180-200 lb in. (20.3-22.5 N·m) of torque.
(c) Connect A-sump oil supply tube and preformed packing. Tighten fitting to
270-300 lb in. (30.5-33.8 N·m) of torque.
20 Change 3
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(d) Connect B-, C-, D-, and E-sump tube. Tighten fitting to 75-91 lb ft
(102-123 N·m) of torque.
WARNING
Electrical power shall be off before connecting or disconnecting
electrical connectors. Electricity causes shock, burns, and death.
(e) Connect electrical connector to lube oil supply.
(f) Connect remaining packager connections per packager's manual.
C. Oil wet D- and E-sump bearings as follows:
(1) Disconnect the D- and E-sump oil supply line fitting on strut 6 of turbine rear
frame (figure 7). Connect hydraulic unit pressurizer, 1C3569, head-end line with
reducer, AN919-8.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(2) Locate D- and E-scavenge lines (figure 8) and place clean container under lines.
Disconnect the two lines. Dispose of drained oil and return container under lines.
8
7
CAUTION
During operation of hydraulic unit pressurizer, 1C3569, observe
head-end pressure gage to verify pressure buildup does not exceed
100 psi (689.4 kPa) or damage to gearbox seals may result.
NOTE
Pump handle of hydraulic unit pressurizer, 1C3569, shall be operated
rapidly through the full piston stroke to ensure that the proper amount
of oil/preservative mixture is supplied to the sump.
(3) Using rear drive adapter, rotate low pressure rotor 5-10 RPM clockwise (aft
looking forward) while operating hydraulic unit pressurizer pump, 1C3569,
handle (maintain 20 psig [137.8 kPa] minimum pressure). Rotate low pressure
rotor and activate pump handle for 2 minutes.
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Figure 7. D- and E-Sump Oil Supply Line
(4) Remove hydraulic unit pressurizer, 1C3569, head-end line from D- and E-sump
oil supply line. Reconnect oil supply line. Tighten fitting to 450-550 lb in.
(50.8-62.1 N·m) of torque.
(5) Reconnect D- and E-scavenge lines and tighten to 650-750 lb in.
(73.4-84.7 N·m) of torque.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(6) Pour oil mixture from container into hydraulic unit pressurizer, 1C3569, reservoir.
If reservoir does not contain approximately 6 quarts (6 liters) (reservoir capacity),
mix an additional 5 percent mixture and fill reservoir.
22 Change 3
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Figure 8. Rear Frame and Scavenge Lines
D. Oil wet B- and C-sump bearings as follows:
(1) Locate B- and C-sump oil supply line (figure 7) and disconnect fitting at main
lube supply manifold. Connect hydraulic unit pressurizer, 1C3569, head-end line
with reducer, AN919-13.
(2) Locate B- and C-scavenge lines (figure 7) and place container under lines.
Disconnect two lines. Dispose of drained oil and return container under lines.
Change 3 23
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CAUTION
During operation of hydraulic unit pressurizer, 1C3569, observe
head-end pressure gage to verify pressure buildup does not exceed
100 psi (689.4 kPa) or damage to gearbox seals may result.
NOTE
• Pump handle of hydraulic unit pressurizer, 1C3569, shall be operated
rapidly through the full piston stroke to ensure the proper amount of
oil/preservative mixture is supplied to the sump.
• Core RPM can be determined by observing rotation of ratchet drive.
A ratchet drive speed of 7 RPM equals core speed of 10 RPM.
(3) Use ratchet in manual drive pad to rotate core 5-10 RPM clockwise (aft looking
forward) while operating hydraulic unit pressurizer pump, 1C3569, handle
(maintain 20 psig [137.8 kPa] minimum pressure). Rotate core and activate pump
handle for 2 minutes.
(4) Remove hydraulic unit pressurizer, 1C3569, head-end line from B- and C-sump
oil supply line. Reconnect oil supply line and tighten fitting to 650-750 lb in.
(73.4-84.7 N·m) of torque.
(5) Reconnect B- and C-scavenge lines and two gaskets. Tighten bolts and nuts to
55-70 lb in. (6.2-7.9 N·m) of torque.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(6) Remove ratchet from gearbox drive pad. Lubricate preformed packing with
lubricating oil, and install preformed packing onto cover plate.
(7) Reinstall cover plate, four washers, and four nuts. Tighten nuts to 55-70 lb in.
(6.2-7.9 N·m) of torque.
(8) Pump all oil/preservative mixture from hydraulic unit pressurizer, 1C3569,
reservoir and agitate using fresh lubricating oil in reservoir. Pump all oil from
reservoir and dispose of oil.
(9) Disconnect reducer from hydraulic unit pressurizer, 1C3569, line and reinstall
-6/-4 reducer, nut, and cap on head-end line.
24 Change 3
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E. Cover or plug all engine openings and unattached fittings. Cover inlet, exhaust, and
VBV openings using moisture barrier paper, if possible.
9. Oil Wetting LM6000 Bearings (Alternate Procedure 2).
WARNING
• Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do
not inhale, ingest, or let this material touch you. Irritant. Per-
sonal protective equipment required. Use mechanical exhaust
ventilation - if not available, use an approved respirator.
• Rust preventive concentrate, Brayco 599: Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
NOTE
The use of rust preventive concentrate, Brayco 599, is optional if
preservation period is less than 15 days.
A. Add Brayco 599, preventive, to lube oil tank to obtain 5 percent mixture.
B. Perform one of the following:
(1) Operate engine at base load for minimum of 10 minutes.
NOTE
Engines that are affected by Service Bulletin LM6000-IND-200
and have not yet implemented the revised VBV schedule should
be preserved at core idle instead of synch idle.
(2) Operate engine at synch idle for minimum of 10 minutes.
(3) Motor engine for minimum of 10 minutes with XN25 greater than 2000 rpm and
XN2 greater than 200 rpm.
Change 3 25
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10. Installed Engine for Greater than 30 Days Preservation.
A. Use of rust preventive concentrate, Brayco 599, in lubricating oil is required.
CAUTION
• Ensure driven equipment is prelubricated or drive shaft is dis-
connected prior to motoring engine. Failure to comply may
result in damage to driven equipment or lack of low pressure
rotor rotation and subsequent insufficient bearing lubrication.
• Do not exceed starter duty cycle when motoring. Hydraulic
starter has no duty cycle limitations except oil temperature shall
be maintained below 140°F (60°C). Pneumatic starter duty
cycle follows:
5 minutes on, 2 minutes off,
5 minutes on, 18 minutes off,
or
10 minutes on, 20 minutes off.
B. Perform paragraphs 7.A through 7.C, as applicable.
C. Perform paragraphs 7.A through 7.C, as applicable, every 30 days. Update engine log
to include oil wetting dates.
(1) Close fuel supply valves per packager's manual.
WARNING
Fuel in liquid, vapor, or mist form is flammable, irritating to the
skin and respiratory tract, and poisonous in the digestive tract.
Remove saturated clothing, wash skin well, don't swallow liquid,
and don't breathe mist or vapor.
(2) Disconnect maintenance outlet hose from engine fuel pump. Drain fuel into
suitable container.
9
WARNING
Lubricating oil, MIL-L-6081, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(3) Remove maintenance drain plug from engine fuel pump. Drain fuel into suitable
container. Discard preformed packing.
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Figure 9. Liquid Fuel Pump
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(4) Lubricate new preformed packing using fuel system preservation oil and install
onto fuel pump maintenance drain plug.
(5) Install maintenance drain plug. Tighten plug to 270-300 lb in. (30.5-33.8 N·m) of
torque. Safety-wire plug.
(6) Remove bolts that secure pressure bypass hose onto engine fuel pump. Drain fuel
into suitable container. Remove hose. Inspect seal gasket for serviceability.
Discard damaged seal gasket.
(7) Remove filter bowl drain plug. Drain fuel into suitable container. Discard
preformed packing.
(8) Lubricate new preformed packing with fuel system preservation oil and install
onto filter bowl drain plug. Install drain plug into filter bowl. Tighten drain plug to
135-150 lb in. (15.2-16.9 N·m) of torque.
(9) Remove interstage pressure tap plug. Discard preformed packing.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
(10) Lubricate new preformed packing with fuel system preservation oil and install on
reducer. Install reducer into interstage pressure tap. Tighten reducer to
135-150 lb in. (15.2-16.9 N·m) of torque.
(11) Connect rod-end hose of fuel system preservation pump, 2C6395, onto interstage
pressure tap fitting. Tighten coupling nut to 450-550 lb in. (50.8-62.1 N·m) of
torque. Ensure remaining pump hoses are plugged.
(12) Fill fuel system preservation pump, 2C6395, with fuel system preservation oil.
(13) Fill engine fuel pump with fuel system preservation oil using fuel system
preservation pump, 2C6395. Continue pumping until oil runs freely from pressure
bypass port.
(14) Install new or serviceable packager-supplied seal gasket onto pressure bypass
hose. Using bolts, install pressure bypass hose onto fuel pump. Tighten bolts to
55-70 lb in. (6.2-7.9 N·m) of torque.
(15) Continue pumping fuel system preservation oil into engine fuel pump until a
minimum of 1 quart (0.9 liter) of clear preservation oil runs freely from pressure
outlet fitting.
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(16) Install pressure outlet hose onto fitting. Tighten fitting to 112-128 lb ft
(152-174 N·m) of torque.
(17) Disconnect fuel system preservation pump, 2C6395.
(18) Remove reducer from interstage pressure tap. Discard preformed packing.
(19) Lubricate new preformed packing with fuel system preservation oil and install
onto interstage pressure tap plug.
(20) Install interstage pressure tap plug into fuel pump. Tighten plug to 135-150 lb in.
(15.2-16.9 N·m) of torque.
D. Perform paragraphs 7.A through 7.C, as applicable, every 30 days. Update engine log
to include oil wetting dates.
11. Noninstalled Engine for up to 30 Days Preservation.
NOTE
If engine is installed in pedestals or dolly, proceed to step C.
A. Container should be stored in an area shaded from direct sunlight and within limits of
normal environment. Engine storage log should be maintained and updated every 30
days, to include recorded humidity condition, oil wetting dates, and desiccant
replacement.
B. For gas turbine to be installed in shipping container, perform the following:
(1) Preserve engine per paragraphs 7.C.(1) or 7.C.(2).
(2) Place 75 bags of new desiccant in container.
(3) Install container lid.
(4) Inspect humidity indicator at least once every 30 days. Indicator should appear
blue, indicating safe humidity conditions. If indicator appears pink, the following
steps must be complied with within 14 days:
(a) Remove cover.
(b) Remove desiccant.
(c) Preserve engine per paragraphs 7.C.(1) or 7.C.(2).
(d) Place 75 bags of new desiccant in container.
Change 3 29
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(e) Reinstall container lid.
C. For gas turbines installed in dolly or pedestals, perform the following:
(1) Engine storage log should be maintained and updated to include oil wetting dates.
(2) Preserve engine per paragraphs 7.C.(1) or 7.C.(2)
12. Noninstalled Engine for Greater than 30 Days Preservation.
NOTE
If engine is installed in pedestals or dolly, proceed to step C.
A. Container should be stored in an area shaded from direct sunlight and within limits of
normal environment. Engine storage log should be maintained and updated every 30
days, to include recorded humidity condition, oil wetting dates, and desiccant
replacement.
B. For gas turbine to be installed in shipping container, preserve liquid fuel pump, if
installed, as follows (figure 9):
NOTE
Fuel pump preservation is not required if preservation period is
less than 30 days.
(1) Close fuel supply valves per packager's manual.
WARNING
Fuel in liquid, vapor, or mist form is flammable, irritating to the
skin and respiratory tract, and poisonous in the digestive tract.
Remove saturated clothing, wash skin well, don't swallow liquid,
and don't breathe mist or vapor.
(2) Disconnect maintenance outlet hose from engine fuel pump. Drain fuel into a
suitable container.
(3) Remove maintenance drain plug from engine fuel pump. Drain fuel into a suitable
container. Discard preformed packing.
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WARNING
Lubricating oil, MIL-L-6081, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(4) Lubricate new preformed packing with fuel system preservation oil and install
onto fuel pump maintenance drain plug.
(5) Install maintenance drain plug. Tighten plug to 270-300 lb in. (30.5-33.8 N·m) of
torque. Safety-wire plug.
(6) Remove bolts that secure pressure bypass hose onto engine fuel pump. Drain fuel
into suitable container. Remove hose. Inspect seal gasket for serviceability.
Discard damaged seal gasket.
(7) Remove filter bowl drain plug. Drain fuel into suitable container. Discard
preformed packing.
(8) Lubricate new preformed packing with fuel system preservation oil and install
onto filter bowl drain plug. Install drain plug into filter bowl. Tighten drain plug
to 135-150 lb in. (15.2-16.9 N·m) of torque.
(9) Remove interstage pressure tap plug. Discard preformed packing.
CAUTION
Ensure connecting fitting is restrained when tightening coupling
nut. Failure to comply may result in part damage.
(10) Lubricate new preformed packing with fuel system preservation oil and install on
reducer. Install reducer into interstage pressure tap. Tighten reducer to
135-150 lb in. (15.2-16.9 N·m) of torque.
(11) Connect rod-end hose of fuel system preservation pump, 2C6395, onto interstage
pressure tap fitting. Tighten coupling nut to 450-550 lb in. (50.8-62.1 N·m) of
torque. Ensure remaining pump hoses are plugged.
(12) Fill fuel system preservation pump, 2C6395, with fuel system preservation oil.
(13) Fill engine fuel pump with fuel system preservation oil using fuel system
preservation pump, 2C6395. Continue pumping until oil runs freely from the
pressure bypass port.
Change 3 31
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(14) Install new or serviceable packager-supplied seal gasket onto pressure bypass onto
hose. Using bolts, install pressure bypass hose onto fuel pump. Tighten bolts to
55-70 lb in. (6.2-7.9 N·m) of torque.
NOTE
The use of rust preventive concentrate, Brayco 599, is required for
preservation period of greater than 30 days.
(15) Preserve engine per paragraphs 7.C.(1) or 7.C.(2).
(16) Place 75 bags of new desiccant in container.
(17) Install container lid.
(18) Inspect humidity indicator at least once every 30 days. Indicator should appear
blue, indicating safe humidity conditions. If indicator appears pink, the following
steps must be complied with within 14 days:
(a) Remove cover.
(b) Remove desiccant.
(c) Preserve engine per paragraphs 7.C.(1) or 7.C.(2)
(d) Place 75 bags of new desiccant in container.
(e) Reinstall container lid.
(f) Inspect humidity indicator at least once every 30 days. If indicator appears
pink, complete corrective actions per steps (18)(a) through (e) within 14 days
and start humidity inspection period again.
C. For gas turbines in a dolly or on a pedestal:
(1) Maintain and update engine storage log to include oil wetting dates.
(2) Preserve liquid fuel pump, if installed, per paragraphs 12.B.(1) through 12.B.(14).
(3) Preserve engine per paragraphs 7.C.(1) or 7.C.(2).
(4) Repeat gas turbine preservation per paragraphs 7.C.(1) or 7.C.(2) every 30 days.
32 Change 3
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13. Engine Depreservation.
A. If required, depreserve lubricating oil tank as follows:
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(1) Drain engine lubricating oil tank per packager's manual.
(2) Remove drain plug from forward side of accessory gearbox. Drain oil into
suitable container. Discard packing.
(3) Lubricate preformed packing with lubricating oil and install onto accessory
gearbox drain plug.
(4) Install accessory gearbox drain plug. Tighten plug to 270-300 lb in.
(30.5-33.8 N·m) of torque.
(5) Fill lubricating oil tank with lubricating oil per packager's manual.
B. If required, depreserve liquid fuel pump as follows:
WARNING
Lubricating oil, MIL-L-6081, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
CAUTION
Do not operate engine without draining fuel system preservation
oil from the engine fuel pump. Failure to comply may result in a
hot start and subsequent engine damage.
(1) Remove maintenance drain plug from engine fuel pump. Drain fuel system
preservation oil into suitable container. Discard packing.
(2) Lubricate new preformed packing using fuel system preservation oil, and install
onto fuel pump maintenance drain plug.
(3) Install maintenance drain plug. Tighten plug to 270-300 lb in. (30.5-33.8 N·m) of
torque.
Change 3 33
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(4) Remove bolts that secure pressure bypass hose to engine fuel pump. Drain fuel
system preservation oil into suitable container. Inspect seal gasket for
serviceability. Discard damaged seal gasket.
(5) Remove filter bowl drain plug. Drain fuel system preservation oil into suitable
container. Discard packing.
WARNING
Fuel in liquid, vapor, or mist form is flammable, irritating
to the skin and respiratory tract, and poisonous in the
digestive tract. Remove saturated clothing, wash skin well,
don't swallow liquid, and don't breathe mist or vapor.
(6) Lubricate preformed packing with fuel and install onto filter bowl drain plug.
Install drain plug into either bowl. Tighten drain plug to 135-150 lb in.
(15.2-16.9 N·m) of torque.
(7) Install new or serviceable packager-supplied seal gasket onto pressure bypass
hose. Using bolts, install pressure bypass hose onto fuel pump. Tighten bolts to
55-70 lb in. (6.2-7.9 N·m) of torque.
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3WP 3012 00
WORK PACKAGE
TECHNICAL PROCEDURES
GAS TURBINE MAINTENANCE DOLLY
REMOVAL AND INSTALLATION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 18
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 17 ...... 5
18 Blank . . . . . . 5
Alphabetical Index
Subject Page
Gas Turbine Installation into Maintenance Dolly, 1C9372......................................................... 3
Gas Turbine Removal from Maintenance Dolly, 1C9372........................................................... 14
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WP 3012 00
1. Introduction.
This work package contains instructions for removing and installing gas turbine in
maintenance dolly.
2. Reference Material.
None required.
3. Support Equipment.
NOTE
Original support equipment ring assembly, 1C9371G01, is
reworked to ring assembly, 1C9371G02, per Tool Bulletin,
LM6000-0243. Jack assembly, 1C9376G01, is replaced by
1C9448G01. Maintenance dolly adapter assembly, 1C9378G02,
is reworked to 1C9378G03, per Tool Bulletin, LM6000-
0245.Maintenance dolly, 1C9372G05, is reworked to
1C9372G06, per Tool Bulletin, LM6000-0244. It is recommended
that maintenance dolly, 1C9372G06, be reworked to 1C9372G07,
per Tool Bulletin LM2500-0254.
Nomenclature Part No.
Ring Assembly, VIGV Case Support 1C9371G02
Maintenance Dolly, External Engine 1C9372G06 or G07
Adapter Set, Assembly, Support - Air Col- 1C9375G03
lector, FWD
Adapter Set, Assembly, Support - Low Pres- 1C9377G01
sure Compressor, FWD
Adapter Assembly, Maintenance Dolly 1C9378G03
- External Engine
Jack Assembly, Support - Compressor Rear 1C9448G01
Frame
Fixture Assembly, Horizontal Lift 1C9625G01
Sling, Lift MSE-53
4. Consumable Material.
None required.
5. Expendable Material.
None required.
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6. Gas Turbine Installation into Maintenance Dolly, 1C9372.
CAUTION
Turbine rear frame supports and either trunnion or air collector
supports are the minimum supports necessary for installing gas
turbine in maintenance dolly. Failure to use the correct supports
may result in gas turbine damage.
A. Install only those supports required for maintenance task being performed.
See figures 1 and 2 to determine which supports are required.
2
1
B. If required, install trunnion pedestals, 1C9378P02 and P03, onto maintenance dolly,
1C9372, with bolts, washers, and nuts. Boltheads face up, washers under both bolts
and nuts. Tighten nuts to 70-80 lb ft (94.9-108.5 N·m) of torque. See figure 3.
3
C. If required, install air collector support pedestals, 1C9378P10, onto maintenance dolly,
1C9372, with bolts, washers, and nuts, washers under nuts. Tighten nuts
finger-tight. See figure 4.
4
D. Using bolts, washers, and nuts, install turbine rear frame (TRF) support pedestals,
1C9378P06, onto maintenance dolly, 1C9372. Boltheads face up, washers under nuts.
Tighten nuts finger-tight. See figure 5.
5
E. Install gas turbine into maintenance dolly, 1C9372, as follows:
NOTE
Height of pedestals can be adjusted to two different positions
depending on maintenance required.
(1) Adjust height of pedestals to lower or higher maintenance position. Secure with
quick-release pins.
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
(2) Lower gas turbine into maintenance dolly, 1C9372.
(3) If required, secure gas turbine trunnions onto trunnion adapters with locknuts.
Tighten locknuts to 50 lb ft (68 N·m) of torque. See figure 3.
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Figure 1. Determine Required Support Equipment
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Figure 2. Maintenance Dolly Supports from 1C9378
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Figure 3. Trunnion Mount Supports (Position 4)
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Figure 4. Air Collector Supports (Position 3)
NOTE
Ensure that air collector support adapter, 1C9375, is installed
on lower forward air collector flange.
(4) If required, adjust air collector support pedestal position on maintenance dolly,
1C9372. See figure 4. Tighten pedestal retaining nuts to 70-80 lb ft
(94.9-108.5 N·m) of torque.
(5) If required, turn adjusting nut to align air collector support pedestal mount with
forward air collector support adapter, 1C9375. Install quick-release pin.
(6) Adjust TRF support pedestal position on maintenance dolly, 1C9372. See
figure 5. Tighten pedestal retaining nuts to 70-80 lb ft (94.9-108.5 N·m) of torque.
Turn support pedestal yoke to align TRF pedestal bracket, 1C9373P35, with gas
turbine rear mount.
(7) Using TRF mount pin, secure gas turbine onto TRF support pedestal bracket,
1C9378P35. Install quick-release pins through TRF mount pins.
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Figure 5. Turbine Rear Frame Supports (Position 6)
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F. Remove horizontal lift fixture, 1C9625, as follows (figure 6):
6
WARNING
Ensure lift fixture is located at the center of gravity before
disconnecting from gas turbine. Failure to comply may
result in gas turbine damage or serious injury.
(1) Slowly release tension on hoist until lift fixture pins rotate freely. Position lift
fixture trolley at center of gravity (CG).
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
(2) Remove TRF fixture quick-release pins. Remove forward lift point quick-release
pin. Raise lift fixture clear of gas turbine.
G. Install compressor rear frame (CRF) support jack assembly, 1C9448, as follows
(figure 7):
7
NOTE
If maintenance dolly supports are positioned at lower height,
proceed to step (2).
(1) Install spacer, 1C9448P13, onto maintenance dolly, 1C9372, cross plate and
secure with screws, washers, and nuts. Screwheads face up, washers under nuts.
Tighten nuts to 420-510 lb in. (47.5-57.6 N·m) of torque.
(2) Install support jack assembly, 1C9448, onto cross plate or spacer, as required.
Secure with screws, washers, and nuts. Screwheads face up, washers under nuts.
Tighten nuts to 420-510 lb in. (47.5-57.6 N·m) of torque.
(3) Install CRF cradle, 1C9448P10, onto support jack assembly arm, 1C9448P05.
Secure with quick-release pin.
(4) Adjust support jack assembly, 1C9448, position on maintenance dolly, 1C9372,
by moving cross plate. Tighten cross plate nuts to 70-80 lb ft (95-108 N·m) of
torque.
(5) Turn nut and rod-end nut, in even increments, until CRF cradle is aligned and
touching CRF.
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Figure 6. Horizontal Lift Fixture, 1C9625 (Sheet 1 of 2)
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Figure 6. Horizontal Lift Fixture, 1C9625 (Sheet 2 of 2)
NOTE
Install low pressure compressor (LPC) support adapters only if
variable inlet guide vane (VIGV) case has been removed.
H. Install LPC supports as follows (figure 8):
8
(1) Install LPC forward support adapters, 1C9377, onto LPC case front flange by
aligning split-line markings on adapter with LPC case split-line. Secure with
bolts, washers, and nuts, washers under nuts. Tighten nuts to 160-210 lb in.
(18.1-23.7 N·m) of torque.
(2) Install universal support pedestals, 1C9378P06, and yoke, 1C9378P08, onto
maintenance dolly, 1C9372, with bolts, washers, and nuts. Boltheads face up,
washers under nuts. Tighten nuts finger-tight.
(3) Adjust height of universal support pedestals to lower or higher maintenance
position. Secure with quick-release pins.
(4) Adjust universal support pedestal position on maintenance dolly, 1C9372.
Tighten pedestal retaining nuts to 70-80 lb ft (95-108 N·m) of torque. Turn
adjusting nut to align yoke with LPC forward support adapter. Install quick-
release pins.
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Figure 7. Compressor Rear Frame Support (Position 5)
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Figure 8. Low Pressure Compressor Supports (Position 2)
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I. Install VIGV stator case supports as follows (figure 9):
9
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
(1) Position VIGV support ring, 1C9371, onto VIGV case front flange or inlet frame
assembly front flange using 1-ton (907 kg) hoist and sling. Secure ring with bolts
and washers. Tighten bolts to 40-60 lb in. (4.5-6.8 N·m) of torque.
(2) Using bolts, washers, and nuts, install universal support pedestals, 1C9378P06,
and yoke, 1C9378P08, onto maintenance dolly, 1C9372. Boltheads face up,
washers under nuts. Tighten nuts finger-tight.
(3) Adjust height of universal support pedestals to lower or higher maintenance
position. Secure with quick-release pins.
(4) Adjust universal support pedestal, 1C9378P06, position on maintenance dolly,
1C9372. Tighten pedestal retaining nuts to 70-80 lb ft (95-108 N·m) of torque.
Turn adjusting nut to align support yoke to VIGV support ring, 1C9371. Install
quick-release pin.
7. Gas Turbine Removal from Maintenance Dolly, 1C9372.
A. Install horizontal lift fixture, 1C9625, as follows (figure 6):
WARNING
Establish and record the center of gravity of the horizontal
lift fixture to prevent fixture from pitching when being dis-
connected from the gas turbine. Failure to comply may
cause serious injury or gas turbine damage.
(1) Attach 15-ton (13,607 kg) hoist to horizontal lift fixture, 1C9265.
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
(2) Raise horizontal lift fixture, 1C9265, to working height. Level fixture by adjusting
trolley. Record CG measurement.
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Figure 9. VIGV Support Ring (Position 1)
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(3) Position horizontal lift fixture, 1C9265, over gas turbine. Secure lift fixture clevis,
1C9625P09, onto rear mounts on turbine rear frame with quick-release pins.
(4) Position lift fixture front frame adapter onto front frame forward lift point. Install
quick-release pin.
CAUTION
Ensure lift fixture trolley is set to 30.1 inches (764.5 mm) for
engines with VIGV installed, and 31.8 inches (807.7 mm) for
engines with inlet frame installed. Incorrect positioning may
cause lift fixture/gas turbine damage.
(5) Position lift fixture trolley to 30.1 inches (764.5 mm) for engines with VIGV
installed, and 31.8 inches (807.7 mm) for engines with inlet frame installed.
Slowly apply small amount of lifting force on hoist. Ensure lift fixture is properly
attached to gas turbine.
(6) Apply sufficient lifting force on hoist to allow gas turbine to float in maintenance
dolly support mounts. Mount pins shall turn freely.
B. Remove VIGV support rings as follows (figure 9):
(1) Adjust universal support pedestal adjusting nut to allow quick-release pins to
rotate freely. Remove quick-release pins.
(2) Attach a 1-ton (907 kg) hoist and sling on VIGV support ring, 1C9371. Apply
sufficient lifting force to VIGV support ring for removal.
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
(3) Remove bolts and washers from VIGV support ring, 1C9371. Remove support
ring.
C. Remove LPC forward support adapters, 1C9377, as follows (figure 8):
(1) Adjust universal support pedestal, 1C9378P06, adjusting nut to allow
quick-release pins to rotate freely. Remove quick-release pins.
(2) Remove bolts, washers, and nuts that secure LPC forward support adapters,
1C9377, onto LPC case. Remove LPC forward support adapters.
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D. Remove CRF support jack assembly, 1C9448, as follows (figure 7):
(1) Adjust support jack rod-end nut to release pressure on CRF.
(2) Adjust support jack knurled nut until CRF cradle quick-release pin turns freely.
Remove quick-release pin and CRF cradle.
E. Adjust universal support pedestal, 1C9378P06, to release tension on TRF mount pins.
See figure 5. Pins shall rotate freely. Remove quick-release pins. Remove TRF mount
pins.
F. Remove forward air collector support adapters, 1C9375, as follows (figure 4):
(1) Adjust air collector support pedestal adjusting nut to allow quick-release pin to
rotate freely.
(2) Remove quick-release pin and forward air collector support adapter, 1C9375.
G. Remove locknuts that secure gas turbine trunnions onto trunnion adapters.
See figure 3.
WARNING
Always use approved equipment and procedures to lift
parts. Stay out from below loads. If the parts accidentally
move or fall, they can cause an injury or kill you.
H. Lift gas turbine free of maintenance dolly, 1C9372.
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WP 3013 00
2WP 3013 00
WORK PACKAGE
TECHNICAL PROCEDURES
GAS TURBINE/SUPPORT PEDESTAL REMOVAL AND
INSTALLATION
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 16
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 16 ...... 5
Alphabetical Index
Subject Page
Gas Turbine Installation onto Support Pedestal.......................................................................... 3
Gas Turbine Removal from Support Pedestal............................................................................. 11
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WP 3013 00
1. Introduction.
This work package contains instructions for removing and installing the gas turbine in the
support pedestals.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Steam/Fuel Manifold Shipping Bracket Fixture Replacement WP 3015 00
3. Support Equipment.
Nomenclature Part No.
Ring Assembly Support - VIGV Stator Case 1C9371G02
Adapter Set Assembly, Support - Air Collec- 1C9375G03
tor, Forward
Adapter Set Assembly, Support - LPC, For- 1C9377G01
ward
Support Pedestals, Storage and Maintenance 1C9384G03/G04
Jack Assembly, Support - CRF 1C9448G02
Fixture Assembly, Engine Lift 1C9625G01
Sling, Lift MSE-53
4. Consumable Material.
None required.
5. Expendable Material.
None required.
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6. Gas Turbine Installation onto Support Pedestal.
CAUTION
Turbine rear frame supports and either trunnion or air collector
supports are the minimum supports necessary for installing gas
turbine in support pedestals. Failure to use correct supports may
result in gas turbine damage.
A. Use only those supports required for the maintenance task being performed. See
figures 1 and 2 to determine which supports are required.
2
1
B. Install gas turbine onto support pedestal, 1C9384, as follows:
(1) If required, secure gas turbine onto trunnion support pedestals, 9448M53, as
follows (figure 3):
3
(a) Align trunnion support pedestals, 9448M53, with gas turbine trunnions.
(b) Using locknuts, secure gas turbine trunnions onto trunnion support pedestals,
9448M53. Tighten locknuts to 50 lb ft (67.8 N·m) of torque.
(2) If required, secure gas turbine onto air collector support pedestals, 9448M52, as
follows (figure 4):
4
NOTE
Ensure that air collector support adapters, 1C9375, are installed on
lower forward air collector flange.
(a) Align air collector support pedestals, 9448M52, with air collector support
adapters, 1C9375.
(b) Adjust support pedestal yokes, as required, and install quick-release pins.
(3) Secure gas turbine onto turbine rear frame (TRF) support pedestals, 9448M84, as
fol-lows (figure 5):
5
(a) Align CRF support pedestals, 9448M84, with gas turbine mounts.
(b) Turn support pedestal yokes, as required, and install mount pins. Mount pins
shall rotate freely. Install quick-release pins through mount pins.
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Figure 1. Determine Required Support Equipment
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Figure 2. Maintenance Pedestals from 1C9384
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Figure 3. Trunnion Support (Position 4)
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Figure 4. Air Collector Support (Position 3)
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Figure 5. Compressor Rear Frame Support (Position 6)
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C. Remove horizontal lift fixture, 1C9625, as follows (figure 6):
6
(1) Slowly release tension on hoist until lift fixture pins rotate freely. Position lift
fixture trolley at center of gravity (CG).
WARNING
• Ensure lift fixture is located at the center of gravity before
disconnecting from gas turbine. Failure to comply may result
in gas turbine damage or serious injury.
• Ensure gas turbine is secured in pedestals and pedestals are
flat on floor before disconnecting lift fixture from gas turbine.
• Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(2) Remove TRF fixture quick-release pins. Remove forward lift point quick-release
pin. Raise horizontal lift fixture, 1C9625, clear of gas turbine.
D. Support gas turbine with compressor rear frame (CRF) support jack assembly,
1C9448, as follows (figure 7):
7
(1) Install CRF support jack assembly, 1C9448, onto support pedestal, 9448M85.
Using bolts and nuts, secure support jack. Tighten nuts to 420-510 lb in.
(47.5-57.6 N·m) of torque.
(2) Install CRF cradle, 1C9448P10, onto CRF support jack assembly, 1C9448.
Secure with quick-release pin.
(3) Position CRF support jack assembly, 1C9448, under gas turbine. Turn knurled nut
and rod-end nut, in even increments, until cradle is aligned and touching CRF.
NOTE
Install LPC support adapters only if VIGV case has been removed.
E. Install low pressure compressor (LPC) support adapters, 1C9377, and secure gas
turbine onto LPC support pedestals as follows (figure 8):
8
(1) Install LPC support adapters, 1C9377, onto LPC case front flange by aligning
split-line markings on adapters with the LPC case split-line. Secure using bolts,
washers, and nuts. Tighten nuts to 160-210 lb in. (18.1-23.7 N·m) of torque.
(2) Align gas turbine support pedestals, 9448M51, with LPC support adapters,
1C9377.
(3) Adjust support pedestal adjusting nuts, as required, and install quick-release pins.
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Figure 6. Horizontal Lift Fixture, 1C9625 (Sheet 1 of 2)
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Figure 6. Horizontal Lift Fixture, 1C9625 (Sheet 2 of 2)
F. Install variable inlet guide vane (VIGV) case support ring assembly, 1C9371, and
secure gas turbine onto VIGV support pedestals as follows (figure 9):
9
(1) Position VIGV case support ring assembly, 1C9371, on VIGV case front flange or
inlet frame assembly front flange using 1-ton (907 kg) hoist and sling. Secure ring
assembly with 27 capscrews and washers. Tighten bolts to 40-60 lb in.
(4.5-6.8 N·m) of torque.
(2) Align gas turbine support pedestals, 9448M51, with ring assembly.
(3) Adjust support pedestal adjusting nuts, as required, and install quick-release pins.
G. Remove fuel/steam manifold shipping fixture bracket assembly per WP 3015 00.
7. Gas Turbine Removal from Support Pedestal.
A. Install horizontal lift fixture, 1C9625, as follows (figure 6):
(1) Attach 15-ton (13,607 kg) hoist onto horizontal lift fixture, 1C9625.
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Figure 7. Compressor Rear Frame Support (Position 5)
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Figure 8. Low Pressure Compressor Support (Position 2)
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Figure 9. VIGV Case Support (Position 1)
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WARNING
• Establish and record the center of gravity of the horizontal
lift fixture to prevent fixture from pitching when being dis-
connected from the gas turbine. Failure to comply may cause
serious injury or gas turbine damage.
• Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(2) Raise horizontal lift fixture, 1C9625, to working height. Level fixture by
adjusting trolley. Record CG measurement.
(3) Position horizontal lift fixture, 1C9625, over gas turbine. Secure lift fixture clevis,
1C9625P09, onto rear mounts on TRF using quick-release pins.
(4) Position horizontal lift fixture, 1C9625, front frame adapter onto front frame
forward lift point. Install quick-release pin.
CAUTION
Ensure lift fixture trolley is set to 30.1 inches (764.5 mm) for
engines with VIGV installed, and 31.8 inches (807.7 mm) for
engines with inlet frame installed. Incorrect positioning may cause
lift fixture/gas turbine damage.
(5) Position lift fixture trolley to 30.1 inches (764.5 mm) for engines with VIGV
installed, and 31.8 inches (807.7 mm) for engines with inlet frame installed.
Slowly apply small amount of lifting force on hoist. Ensure lift fixture is properly
attached to gas turbine.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(6) Apply sufficient lifting force on hoist to allow gas turbine to float in support
mounts. Mount pins shall turn freely.
B. Remove fuel/steam manifold shipping fixture bracket assembly per WP 3015 00.
C. Remove VIGV case support ring assembly, 1C9371, as follows (figure 9):
(1) Adjust support pedestal adjusting nuts to allow quick-release pins to rotate freely.
Remove quick-release pins.
(2) Attach 1-ton (907 kg) hoist and sling to VIGV case support ring assembly,
1C9371. Take up slack on hoist.
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WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(3) Remove capscrews and washers from ring assembly. Remove ring assembly.
D. Remove LPC forward support adapters, 1C9377, as follows (figure 8):
(1) Adjust support pedestal adjusting nuts to allow quick-release pins to rotate freely.
Remove quick-release pins. Remove pedestals.
(2) Remove bolts, washers, and nuts that secure LPC support adapters, 1C9377, onto
LPC case. Remove LPC support adapters.
E. Remove CRF support jack assembly, 1C9448, as follows (figure 7):
(1) Adjust CRF support jack assembly, 1C9448, rod-end nut to release pressure on
CRF.
(2) Adjust CRF support jack assembly, 1C9448, adjusting nut until CRF cradle
quick-release pin turns freely. Remove quick-release pin and CRF cradle.
(3) Remove bolts and nuts that secure CRF support jack assembly, 1C9448, to
support ped-estal, 9448M54. Remove support jack.
F. Remove CRF support, 1C9448M84, as follows (figure 5):
(1) Adjust support pedestal adjusting nut to release tension on mount pins. Pins shall
rotate freely. Remove quick-release pins. Remove mount pins.
G. Remove air collector support pedestals as follows (figure 4):
(1) Turn support pedestal yoke to allow quick-release pin to rotate freely.
(2) Remove quick-release pin.
H. Remove locknuts that secure gas turbine trunnions onto trunnion adapters on support
pedestals, 9448M53P02. See figure 3.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
I. Lift gas turbine free of support pedestals.
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WP 3014 00
0WP 3014 00
WORK PACKAGE
TECHNICAL PROCEDURES
GAS TURBINE IN SHIPPING CONTAINER
REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 18
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 17 ...... 5
18 Blank . . . . . . 5
Alphabetical Index
Subject Page
Gas Turbine Installation into Shipping Container ...................................................................... 12
Gas Turbine Removal from Shipping Container ........................................................................ 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 3014 00
1. Introduction.
This work package contains instructions for removing and installing the gas turbine in the
shipping container. Refer to paragraph 3 for a list of applicable shipping container part numbers.
2. Reference Material.
None required.
3. Support Equipment.
Nomenclature Part No.
Dolly Assembly, Gas Turbine Changeout 1C9354G03
Adapter Set, Air Collector Support 1C9375G03
Fixture Assembly, Horizontal Lift 1C9625G01
Container, Shipping and Storage - Gas turbine See list below
LM6000 PC, PD, PF, PG, and PH Gas Turbine Shipping and Storage Containers
Stencil for all Stencil for Stencil for Stencil for Stencil for
Containers 106C7154P04 106C7154P05 106C7154P06 106C7154P07
Total Weight 30,619 lb 30,619 lb 30,619 lb 30,819 lb
(13,889 kg) (13,889 kg) (13,889 kg) (13,979 kg)
Container 10,619 lb 10,619 lb 10,619 lb 10,819 lb
(4817 kg) (4817 kg) (4817 kg) (4907 kg)
Maximum Gas 20,000 lb 20,000 lb 20,000 lb 20,000 lb
Turbine Weight (9072 kg) (9072 kg) (9072 kg) (9072 kg)
Cube 1274 cu ft 1274 cu ft 1274 cu ft 1274 cu ft
(36 cu m) (36 cu m) (36 cu m) (36 cu m)
Width 8.5 ft (2.6 m) 8.5 ft (2.6 m) 8.5 ft (2.6 m) 8.5 ft (2.6 m)
Height 8.3 ft (2.5 m) 8.3 ft (2.5 m) 8.3 ft (2.5 m) 8.3 ft (2.5 m)
Length 18.2 ft (5.6 m) 18.2 ft (5.6 m) 18.2 ft (5.6 m) 18.2 ft (5.6 m)
Note: The weight of container, 106C7154, with addition of air ride (soft ride) kit, is
increased by 2000 pounds (907 kg).
4. Consumable Material.
Nomenclature Specification
Desiccant MIL-D-3464
5. Expendable Material.
None required.
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6. Gas Turbine Removal from Shipping Container.
A. Prepare shipping container for gas turbine removal as follows:
WARNING
Release pressure from shipping container to prevent injury
when separating container halves.
CAUTION
Ensure crane is of sufficient lifting capacity when moving ship-
ping container with engine installed, into and out of truck.
(1) Depressurize shipping container by pressing button located in center of relief
valve. See figure 1.
1
(2) Rotate tee bolts so that boltheads drop into lower flange recess. See figure 3.
2
(3) Attach 4-ton (3,628 kg) hoist and sling to two lifting rings along top center of lid.
Attach two control lines to opposite ends of lid.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(4) Raise lid straight up until clear of gas turbine and place on wood blocks. Remove
hoist and sling.
(5) Lower four corner posts. See figure 2, view C.
3
B. Remove gas turbine from container as follows:
(1) Remove five bolts and nuts from air collector lower forward flange on each side.
See figure 4.
4
(2) Remove two aft bolts that secure No. 1 electrical interface panel onto support
bracket. Loosen forward bolt on support bracket and swing bracket clear of air
collector flange.
(3) Using five bolts, install air collector support adapters, 1C9375, onto air collector
lower forward flange. Tighten bolts to 480-570 lb in. (54.3-64.4 N·m) of torque.
See figure 5.
5
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Figure 1. LM6000 Shipping Container Pressure Relief Valves
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Figure 2. Shipping Container
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Figure 3. Shipping Container Base
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Figure 4. No. 1 Electrical Interface Panel Support Bracket
WARNING
Establish and record the center of gravity of the horizontal lift
fixture to prevent fixture from pitching when being disconnected
from the gas turbine. Failure to comply may cause serious injury
or gas turbine damage.
(4) Attach 15-ton (13,607 kg) hoist onto horizontal lift fixture, 1C9625.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(5) Raise horizontal lift fixture, 1C9625, to working height. Level fixture by
adjusting trolley. Record center of gravity (CG) measurement.
(6) Position horizontal lift fixture, 1C9625, over gas turbine. Using quick-release
pins, secure lift fixture clevis, 1C9625P09, onto rear mounts on turbine rear
frame. See figure 6.
6
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Figure 5. Mounting Hardware
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Figure 6. Horizontal Lift Fixture and Changeout Dolly
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(7) Position lift fixture front frame adapter onto front frame forward lift point. Install quick-
release pin. See figure 6.
CAUTION
Ensure lift fixture trolley is set to 30.1 inches (764.5 mm) for engines with
VIGV installed, and 31.8 inches (807.7 mm) for engines with inlet frame
installed. Incorrect positioning may cause lift fixture/gas turbine damage.
(8) Position lift fixture trolley to 30.1 inches (764.5 mm) for engines with VIGV installed, and
31.8 inches (807.7 mm) for engines with inlet frame installed. Slowly apply small amount
of lifting force on hoist. Ensure lift fixture is properly attached to gas turbine.
(9) Remove nuts, lockwashers, and flat washers from trunnions. See figure 7.
(10) Remove four bolts and lockwashers that secure upper pillow blocks. Remove upper pillow
blocks. See figure 2.
(11) Apply sufficient lifting force on hoist to allow gas turbine to float in rear mounts. Rear
mount pins shall turn freely.
7
Figure 7. Trunnion Mount
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WARNING
• Use correct lifting equipment and techniques. Stay out from under
suspended loads to prevent injury.
• Ensure hoist and lift fixture are aligned prior to removing rear
mount pins. Failure to comply may result in gas turbine shifting,
causing serious injury.
CAUTION
Ensure rear mount links do not drop onto gas turbine components while
gas turbine is being raised. Gas turbine damage may result.
(12) Remove rear mount pins and raise gas turbine clear of container.
C. Install gas turbine into changeout dolly, 1C9354, as follows:
WARNING
Use correct lifting equipment and techniques. Stay out from under sus-
pended loads to prevent injury.
(1) Slowly lower gas turbine into changeout dolly, 1C9354. Align air collector
support adapters, 1C9375, with changeout dolly, forward supports. Install
quick-release pin on both sides. See figure 5.
(2) Push right rear support clevis pin inboard and align with turbine rear mount. Install
mount pin. Install quick-release pin through mount pin. Install
quick-release pin through rear mount support and clevis pin.
(3) Push left rear support clevis pin inboard and align with turbine rear mount by adjusting
support. Install mount pin. Install quick-release pin through mount pin. Install quick-
release pin through rear mount support and clevis pin.
(4) Position lift fixture trolley at CG. Slowly release tension on hoist until lift fixture pins
rotate freely.
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WARNING
• Ensure lift fixture is located at the center of gravity before discon-
necting from gas turbine. Failure to comply may result in gas tur-
bine damage or serious injury.
• Use correct lifting equipment and techniques. Stay out from under
suspended loads to prevent injury.
(5) Remove two turbine rear frame fixture quick-release pins. Remove forward lift point
quick-release pin. Raise lift fixture clear of gas turbine.
(6) Remove straight pin, washers, and cotter pin from turbine rear frame sway mount. See
figure 8.
8
7. Gas Turbine Installation into Shipping Container.
CAUTION
Ensure crane is of sufficient lifting capacity when moving shipping container with
engine installed, into and out of truck.
NOTE
• Prior to installation of the gas turbine into the shipping container the fuel sys-
tem must be drained and purged according to the procedure in WP 3010 00.
• Prior to installation of gas turbine into the shipping container, make sure
appropriate shipping container is being used. Refer to paragraph 3 for a list of
applicable shipping container part numbers.
A. Prepare shipping container (refer to paragraph 3 for applicable part numbers) for gas turbine
installation as follows:
(1) Remove four bolts and lockwashers that secure trunnion mount upper pillow blocks.
Remove upper pillow blocks. See figure 2.
(2) Loosen four bolts that secure trunnion mount lower pillow blocks, to provide for lateral
adjustment.
(3) Position aft mount links outboard. Loosen right mount link jamnut.
(4) Lower four corner posts.
(5) Position aft mount links to proper position (farthest aft location).
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Figure 8. Turbine Rear Frame Sway Mount
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B. Remove gas turbine from changeout dolly, 1C9354, as follows:
(1) Install sway mount straight pin, washers, and cotter pin into turbine rear frame
6:00 o'clock position. One washer under pinhead, one washer under cotter pin.
See figure 8.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(2) Attach 15-ton (13,607 kg) hoist to horizontal lift fixture, 1C9625. Raise fixture
to working height. Level fixture by adjusting trolley. Record CG measurement.
(3) Position horizontal lift fixture, 1C9625, over gas turbine. Using quick-release
pins, secure lift fixture clevis, 1C9625P09, onto rear mounts on turbine rear
frame. See figure 6.
(4) Position lift fixture front frame adapter onto front frame forward lift point.
Install quick-release pin.
CAUTION
Ensure lift fixture trolley is set to 30.1 inches (764.5 mm) for
engines with VIGV installed, and 31.8 inches (807.7 mm) for
engines with inlet frame installed. Incorrect positioning may
cause lift fixture/gas turbine damage.
(5) Position lift fixture trolley to 30.1 inches (764.5 mm) for engines with VIGV
installed, and 31.8 inches (807.7 mm) for engines with inlet frame installed.
Slowly apply small amount of lifting force on hoist. Ensure lift fixture is prop-
erly attached to gas turbine.
WARNING
• Ensure hoist and lift fixture are aligned before removing
changeout dolly mount pins. Failure to comply may result in
gas turbine shifting causing serious injury.
• Ensure mount pins turn freely before removing.
(6) Apply sufficient lifting force on hoist to allow gas turbine to float in mounts.
Mount pins shall turn freely.
(7) Remove air collector support adapter quick-release pins. See figure 5.
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(8) Remove quick-release pins that secure mount pins onto turbine rear frame.
Remove mount pins.
(9) Remove quick-release pins that secure clevis pins onto support. Pull clevis pins
outboard for maximum clearance.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(10) Raise gas turbine clear of changeout dolly, 1C9354.
C. Install gas turbine into shipping container as follows:
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
CAUTION
Ensure rear mount links do not drop onto gas turbine components
while gas turbine is being lowered into container, or gas turbine
damage may result.
NOTE
Prior to installation of gas turbine into the shipping container, make
sure appropriate shipping container is being used. Refer to
paragraph 3 for a list of applicable shipping container part numbers.
(1) Lower gas turbine into shipping container. Align trunnion mounts with lower
pillow blocks. Align aft mount links with turbine rear frame mounts. See
figure 2.
(2) Install left rear mount pin, washers, and cotter pin. One washer under pinhead,
one washer under cotter pin. Secure pin with cotter pin.
(3) Adjust right rear mount link, as required, until mount pin can be inserted freely.
Install mount pin, washers, and cotter pin. One washer under pinhead, one
washer under cotter pin. Secure pin with cotter pin. Hand-tighten adjustable link
jamnut.
(4) Slowly release tension on hoist.
(5) Using four bolts and lockwashers, install upper pillow blocks (figure 2). Tighten
bolts to 50-70 lb ft (67.8-94.9 N·m) of torque.
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(6) Install flat washers, lockwashers, and nuts onto gas turbine trunnions. Tighten
nuts to 200-250 lb ft (271.2-339.0 N·m) of torque.
(7) Tighten lower pillow block bolts to 50-70 lb ft (67.8-94.9 N·m) of torque.
(8) Position lift fixture trolley at CG. Slowly apply sufficient lifting force to allow lift
fixture pins to rotate freely.
WARNING
• Ensure lift fixture is located at the center of gravity before
disconnecting from gas turbine. Failure to comply may result
in gas turbine damage or serious injury.
• Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(9) Remove two turbine rear frame lift fixture quick-release pins. Remove forward
lift point quick-release pin. Raise lift fixture clear of gas turbine.
(10) Remove five bolts that secure air collector support adapters, 1C9375, onto air
collector lower forward flange. Remove support adapters.
(11) Position No. 1 electrical interface panel bracket. Secure bracket onto air collector
with two bolts and nuts. Tighten nuts finger-tight. Install eight remaining bolts
and nuts onto air collector forward flange. Tighten eight air collector nuts to
480-570 lb in. (54.3-64.4 N·m) of torque.
(12) Install two bolts that secure No. 1 electrical interface panel onto bracket. Tighten
three bolts to 55-70 lb in. (6.3-7.9 N·m) of torque. Tighten two nuts that secure
bracket onto air collector to 480-570 lb in. (54.3-64.4 N·m) of torque.
D. Install shipping container cover as follows:
(1) Raise four corner posts.
(2) Fill desiccant container, as required.
(3) Ensure flange and gasket on enclosure base are clean and serviceable.
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NOTE
• Ensure tee bolts are aligned in recess and nuts have been loosened
prior to installing the lid on the shipping container.
• Up to two tee bolts per side (eight total) can be missing, provided
missing tee bolt locations are not adjacent and are not at the corners.
(4) Attach 4-ton (3,628 kg) hoist and sling to two lifting rings at top of lid. Attach two
control lines to opposite ends of lid.
WARNING
Ensure lift fixture is located at the center of gravity before dis-
connecting from gas turbine. Failure to comply may result in gas
turbine damage or serious injury.
(5) Lower lid straight down over gas turbine, aligning forward and aft guide pins.
Ensure flanges seat.
(6) Remove hoist, sling, and guide ropes.
(7) Rotate tee bolts until long side of bolthead is perpendicular to flange. Tighten tee
bolt nuts to 420-510 lb in. (47.5-57.6 N·m) of torque. Re-torque tee bolts to
420-510 lb in. (47.5-57.6 N·m) of torque. Continue to re-torque until all tee bolts
are tightened to 420-510 lb in. (47.5-57.6 N·m) of torque. See figure 3.
Change 5 17/(18 Blank)
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SWP 3014 01
SUBORDINATE WORK PACKAGE
TECHNICAL PROCEDURES
AIR RIDE KIT INSTALLATION
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 10 ................. 5
Alphabetical Index
Subject Page
Air Ride Kit Installation.......................................................................................................... 3
Air Ride Kit Removal. ............................................................................................................ 9
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1. Introduction.
This work package provides instructions for installing and removing the LM6000 gas turbine shipping
container air ride kit. The air ride kit is designed to reduce the possibility of bearing damage in gas
generators and gas turbines installed in shipping containers, in areas where trucks and trailers with air
ride suspensions may not be available.
The air ride kit is made up of two box assemblies. Each assembly is made up of two interconnected air
ride boxes. During shipping, one air ride box assembly is attached to each end of the gas turbine shipping
container.
Each air ride box assembly weighs approximately 850 pounds (386 kg).
2. Reference Material. None required.
3. Support Equipment Required.
Nomenclature Part No.
Kit, Air Ride 00202050000
Container, Shipping - LM6000 106C7154P04-P07
4. Consumable Material.
Nomenclature Specification
Compressed air
5. Expendable Material. None required.
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6. Air Ride Kit Installation.
NOTE
• Air ride kit can only be installed on containers that have a dark blue painted
base (bottom section of container).
• Two interconnected air ride boxes make up each air ride box assembly.
A. Open air pressure release valves (9, figure 1), two valves inside each of the four air
ride boxes (1 and 15), to release any residual air pressure present in the air bags.
B. Remove bolts (5) that secure air ride box lids (2) to boxes. Open box lids.
WARNING
Always use approved equipment and procedures to lift parts. Stay out from
below loads. If the parts accidentally move or fall, they can cause an injury or
death.
CAUTION
Yellow lifting bars on air ride boxes are for installation or removal of air ride
boxes only. Do not attempt to lift gas turbine shipping container using air ride
box lifting bars, or damage to air ride box, shipping container, or gas turbine
may result.
C. Using forklift, or overhead hoist with a minimum 1000-pound (454 kg) capacity, connected
to yellow lifting bars (4), move left side air ride box (1) into position at end of gas turbine
shipping container (11). Align boltholes in air ride box to boltholes in gas turbine shipping
container.
NOTE
Do not fully tighten bolts until both air ride boxes and connecting channel have
been installed with all bolts hand-tight.
D. Secure left side air ride box (1) to gas turbine shipping container with 12 bolts (3). Tighten bolts
hand-tight.
E. Repeat steps 6.C. and 6.D. to install right side air ride box (15) to gas turbine shipping
container.
F. Install connecting channel (13) to air ride boxes (1 and 15), aligning boltholes in connecting
channel with boltholes in air ride boxes. Secure connecting channel to each air ride box with
four bolts (12). Tighten bolts hand-tight.
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Figure 1. Air Ride Kit (Sheet 1 of 3)
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Figure 1. Air Ride Kit (Sheet 2 of 3)
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Figure 1. Air Ride Kit (Sheet 3 of 3)
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G. Tighten bolts (3) to 69-81 lb ft (94-109 N·m) of torque.
H. Tighten bolts (12) to 69-81 lb ft (94-109 N·m) of torque.
I. Repeat steps 6.C. through 6.H. to install second air ride box assembly to other end of gas
turbine shipping container.
J. Verify, and adjust as necessary, that adjustable shock dampers (14) are set to the No. 6 setting.
K. Close lids on the four air ride boxes and secure each lid with two bolts (5). Tighten bolts to
69-81 lb ft (94-109 N·m) of torque.
L. Open the two air shutoff valves (6) inside each of the four air ride boxes.
WARNING
Serious injury can occur when applying pneumatic pressure. Eye protection is
required. Relieve pressure before disconnecting lines and fittings.
M. Using compressed air and air pressure gauges (7), apply air to air inlet valves (8) to inflate air
bags to 50-60 psig (345-413 kPa gage) for the gas turbine model to be transported.
NOTE
If gas turbine shipping container is to be transported empty, it is acceptable, but
not a requirement, to pressurize air bags.
N. After air bags are pressurized to the correct air pressure setting, remove compressed air source
and close the two air shutoff valves (6) inside each of the four air ride boxes.
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WARNING
Always use approved equipment and procedures to lift parts. Stay out from
below loads. If the parts accidentally move or fall, they can cause an injury or
death.
CAUTION
Yellow lifting bars on air ride boxes are for installation or removal of air ride
boxes only. Do not attempt to lift gas turbine shipping container using air ride
box lifting bars, or damage to air ride box, shipping container, or gas turbine
may result.
NOTE
If gas turbine shipping container is lifted with a forklift or overhead crane or
hoist, air ride box assemblies may sag off ends of shipping container. This is
acceptable and will not damage the air ride box assemblies or container.
O. Using forklift, or overhead crane or hoist, install gas turbine shipping container on truck trailer
bed.
CAUTION
During transport of gas turbine, make sure shipping container is not directly
chained to or in direct contact with trailer bed, or damage to gas turbine
bearings may result.
P. Secure air ride boxes on each corner of gas turbine shipping container to truck trailer bed,
using chains between trailer and tie down rings (10) on air ride box (figure 2). Make sure
clearance between gas turbine shipping container (11) and bed of truck is between 2-3 inches
(51-76 mm). Gas turbine shipping container must not be chained to or in direct contact with
trailer bed.
Q. If clearance between gas turbine shipping container (11) and bed of truck is not between
2-3 inches (51-76 mm), remove tie-down chains and verify air ride box inflation pressure of
50-60 psig (345-413 kPa gage).
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7. Air Ride Kit Removal.
WARNING
Always use approved equipment and procedures to lift parts. Stay out from
below loads. If the parts accidentally move or fall, they can cause an injury or
death.
CAUTION
Yellow lifting bars on air ride boxes are for installation or removal of air ride
boxes only. Do not attempt to lift gas turbine shipping container using air ride
box lifting bars, or damage to air ride box, shipping container, or gas turbine
may result.
NOTE
If gas turbine shipping container is lifted with a forklift or overhead crane, air ride
kits may sag off ends of shipping container. This is acceptable and will not damage
the kits or container.
A. If necessary, using forklift or overhead crane or hoist, remove gas turbine shipping
container from truck trailer bed and place on shop floor or other suitable surface.
B. Open the two air shutoff valves (6, figure 1) inside each of the four air ride boxes (1 and 15).
C. Open two air pressure release valves (9) inside each of the four air ride boxes, to release air
pressure present in the air bags.
D. Remove bolts (12) that secure connecting channel (13) to left and right air ride boxes (1 and
15). Remove connecting channel.
E. Remove bolts (5) that secure air ride box lids (2) to air ride boxes. Open box lids.
F. Remove bolts (3) that secure air ride boxes to gas turbine shipping container (11).
G. Using forklift, or overhead hoist with a minimum 1000-pound (454 kg) capacity, connected to
yellow lifting bars (4), remove each air ride box from gas turbine shipping container (11).
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Figure 2. Tie-Down of Air Ride Box to Truck Trailer Bed
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WP 3015 00
2WP 3015 00
WORK PACKAGE
TECHNICAL PROCEDURES
STEAM/FUEL MANIFOLD SHIPPING BRACKET
FIXTURE REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-6 ...... 0
Alphabetical Index
Subject Page
Steam/Fuel Manifold Shipping Bracket Fixture Assembly Installation ..................................... 3
Steam/Fuel Manifold Shipping Bracket Fixture Assembly Removal......................................... 6
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 3015 00
1. Introduction.
This work package contains instructions for removing and installing the steam/fuel
manifold shipping bracket fixture assembly.
2. Reference Material.
None required.
3. Support Equipment.
NOTE
Shipping bracket fixture assembly, 1C9381G02, is usable on gas turbines
that do not have a steam manifold. Shipping bracket fixture assembly,
1C9381G02, only contains parts to support the fuel
manifold.
Nomenclature Part No.
Fixture Assembly, Shipping Bracket - 1C9381G01
Steam/Fuel Manifold
Fixture Assembly, Shipping Bracket - 1C9381G02
Steam/Fuel Manifold
4. Consumable Material.
Nomenclature Specification
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
None required.
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WP 3015 00
6. Steam/Fuel Manifold Shipping Bracket Fixture Assembly Installation.
See figure 1.
1
A. Apply thread lubricant to threads of all screws.
B. Using screw, washer, and nut, install single leg bracket onto aft support tube. Washer
under nut, screwhead faces aft. Tighten nut finger-tight.
C. Using screws, washers, and nuts, install double leg bracket onto aft support tube.
Washers under nuts, screwheads face aft. Tighten nuts finger-tight.
D. Position aft support tube over compressor rear frame (CRF) aft flange. Using screws,
washers, and nuts, secure single and double leg brackets onto CRF gas turbine mount
brackets. Washers under nuts, screwheads face aft. Tighten nuts finger-tight.
E. Remove manifold adapters from left-hand (LH) and right-hand (RH) support tubes.
F. Slide LH and RH support tubes into air collector brackets. Using screws, washers, and
nuts, secure LH and RH support tubes under aft support bracket. Washers under nuts,
screwheads face up. Tighten nuts finger-tight.
G. Install manifold adapters so that slots slide over pins on LH and RH support tubes.
Using screws and nuts, secure manifold adapters to LH and RH support tubes.
Screwheads face outward. Tighten nuts finger-tight.
NOTE
Misalignment between manifold adapters and fuel/steam manifold
brackets may indicate that packager's supporting stanchions are
located incorrectly.
H. Check alignment between manifold adapters and fuel/steam manifold brackets. Install
screws finger-tight.
I. Tighten nuts that secure manifold adapters onto LH and RH support tubes to
160-210 lb in. (18.1-23.7 N·m) of torque.
J. Install screws, washers, and nuts that secure LH and RH support tubes onto air
collector brackets. Screwheads face up, washers under nuts. Tighten nuts to
160-210 lb in. (18.1-23.7 N·m) of torque.
K. Tighten nuts that secure single and double leg brackets onto CRF gas turbine mount
brackets to 160-210 lb in. (18.1-23.7 N·m) of torque.
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Figure 1. Steam/Fuel Manifold Shipping Bracket Fixture Assembly, 1C9381 (Sheet 1 of 2)
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Figure 1. Steam/Fuel Manifold Shipping Bracket Fixture Assembly, 1C9381 (Sheet 2 of 2)
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L. Tighten nuts that secure single and double leg brackets onto aft support tube to
160-210 lb in. (18.1-23.7 N·m) of torque.
M. Tighten nuts that secure LH and RH support tubes onto aft support tube to
160-210 lb in. (18.1-23.7 N·m) of torque.
N. Tighten screws securing manifold adapters to fuel/steam manifold brackets to
190-230 lb in. (21.5-26.0 N·m) of torque.
7. Steam/Fuel Manifold Shipping Bracket Fixture Assembly Removal.
See figure 1.
CAUTION
Ensure that fuel and steam manifolds are securely attached onto
the packager's supporting stanchions before removing shipping
bracket fixture assembly.
A. Remove nuts, washers, and screws that secure LH and RH support tubes onto air
collector brackets.
B. Remove screws that secure manifold adapters onto fuel/steam manifold brackets.
C. Remove nuts, washers, and screws that secure manifold adapters onto LH and RH
support tubes. Remove manifold adapters.
D. Remove nuts, washers, and screws that secure LH and RH support tube onto aft
support tube. Remove LH and RH support tube.
E. Remove nuts, washers, and screws that secure single and double leg brackets onto
CRF gas turbine mount brackets. Remove aft support tube with assembled brackets.
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WP 3017 00
2WP 3017 00
WORK PACKAGE
TECHNICAL PROCEDURES
LOW PRESSURE TURBINE (LPT) MODULE IN
SHIPPING CONTAINER REPLACEMENT
(LEVEL 2 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 16
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 16 ...... 6
Alphabetical Index
Subject Page
LPT Module Installation into Shipping Container...................................................................... 13
LPT Module Removal from Shipping Container........................................................................ 3
Change 6 1
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WP 3017 00
1. Introduction.
This work package contains instructions for removing and installing the LPT module in the
shipping container utilizing a single hoist.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Low Pressure Turbine (LPT) Module Replacement WP 2710 00
3. Support Equipment.
Nomenclature Part No.
Fixture, Forward Restrain - LPT 1C9338G02
Rotor/Stator
Strongback, Lift, Turn and Restrain - LPT 1C9613G02
Module
Fixture, Adjustable C.G. Horizontal Lift - 1C9627G01
Heavy Purpose
Dolly, Storage, LPT Module 1C9632G01
Container, Shipping - LPT 106C7158P05
Container, Shipping - LPT 106C7158P02-P04 (ALT)
4. Consumable Material.
Nomenclature Specification
Desiccant MIL-D-3464
5. Expendable Material.
None required.
2 Change 6
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WP 3017 00
6. LPT Module Removal from Shipping Container.
A. Remove top from shipping container, 106C7158, as follows:
(1) Depressurize shipping container by pressing button located in center of relief
valve,figure 1, sheet 1.
1
WARNING
Release pressure from shipping container to prevent injury when
separating container halves.
(2) Loosen nuts on tee-head bolts that secure shipping container top. Rotate tee-head
bolts so boltheads drop into lower flange recess (figure 1, sheet 2, section A-A).
2
(3) Attach 2-ton (1,814.4 kg) hoist and sling to four lifting rings along sides of top.
Attach two control lines to opposite ends of top.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(4) Raise top straight up until clear of module and place on wood blocks. Remove
hoist and sling.
B. Remove LPT module from shipping container as follows (figure 2):
(1) Lower four alignment tubes, located in corners of the container, by pulling cotter
pin, view A.
(2) Remove shaft restraint lock from center of LPT rotor shaft by turning rod until
lock is removed, view B.
(3) Install strongback fixture, 1C9613, onto LPT module per WP 2710 00. Use
two-leg sling and 10-ton (9,071.9 kg) hoist to install strongback.
(4) Remove 16 capscrews, washers, and nuts that secure support plate to mounting
frame.
(5) Lift module from container.
(6) Remove four capscrews, washers, and nuts that secure center shaft restraint and
extension assembly to mounting frame, view B. Remove center shaft restraint and
extension assembly.
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Figure 1. Shipping Container, 106C7158 (Sheet 1 of 2)
4 Change 6
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WP 3017 00
Figure 1. Shipping Container, 106C7158 (Sheet 2 of 2)
Change 6 5
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Figure 2. Shipping Container Setup (Sheet 1 of 3)
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Figure 2. Shipping Container Setup (Sheet 2 of 3)
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Figure 2. Shipping Container Setup (Sheet 3 of 3)
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NOTE
Pivot brace consists of a top and bottom piece. Both pieces are required for
PA Uprate, PC, and PD models.
(7) Remove four capscrews, washers, and nuts that secure pivot braces (sheet 1) in corner of
container. If top pivot brace is not attached to bottom brace, secure using two bolts and
nuts, view D.
(8) Position pivot brace in center of mounting frame by engaging pins in brace in holes in
frame. Secure pivot brace onto frame using two bolts and nuts at curved end.
(9) Remove quick-release pins from both clevis mounts.
(10) Rotate module until top vertical centerline is toward clevis mounts and 6:00 o'clock posi-
tion is toward center of container.
(11) Lower module and install trunnion pins, sheet 2, view C, into clevis mounts. Install
quick-release pins.
(12) Slowly rotate module in clevis mounts to horizontal position until strongback fixture,
1C9613, rests on pivot brace in center of container.
(13) Remove sling and install adjustable CG lift fixture, 1C9627, to strongback fixture,
1C9613.
(14) Switch hoist from strongback fixture, 1C9613, to adjustable CG lift fixture, 1C9627.
(15) Raise module enough to take load off pivot brace but leave module retained in clevis
mounts.
(16) Remove 24 capscrews, lockwashers, and 12 clamps that attach support plate to module
foward flange.
(17) Slowly slide LPT module away from support plate. Support plate will remain in clevis
mounts.
(18) Raise module from container and either install on gas turbine per WP 2710 00 or install
in storage dolly, 1C9632, as follows:
(a) Install adapter plate, 1C9632P08, to LPT case foward flange and secure with five
tooling screws and nuts. Tighten nuts to 70–110 lb in. (7.9–12.4 N·m) of torque.
(b) Lower module onto dolly, 1C9632, and secure adapter plate, figure 3, to forward
posts with ball lock pins.
3
Change 6 9
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Figure 3. LPT Module Storage Dolly and Restrain Fixture
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(c) Install LPT restrain fixture, 1C9338, onto forward end of module as follows:
1 Attach hoist to frame, 1C9338P02.
2 Turn three pointers to disengage position.
3 Install frame, 1C9338P02, into LPT shaft until seated.
4 Turn three pointers to ENGAGE. Tighten knurled jamnut.
5 Secure fixture to LPT case using 13 capscrews. Install capscrews with heads on
LPT case flange.
6 Tighten 1C9338 capscrews to 70–110 lb in. (7.9–12.4 N·m) of torque.
7 If fixture flange does not mate to LPT case or pointers cannot be engaged, pro-
ceed as follows:
a Remove screws that secure lock blocks, 1C9613P02, onto strongback fix-
ture, 1C9613. Remove lock blocks.
b Remove nut ring from strongback ring adapter.
c Reposition LPT rotor, forward or aft, as required.
d Secure fixture per steps 1 through 6.
CAUTION
Do not remove strongback until LPT rotor is restrained at the forward end,
either by the forward restrain fixture, installation in the vertical shipping con-
tainer, or by connection to the engine.
(d) Remove strongback fixture, 1C9613, as follows (figure 4).
4
1 Remove bolts that secure lock blocks onto strongback fixture, 1C9613. Remove
lock blocks, 1C9613P02.
2 Remove nut ring, 1C9613P06, from strongback ring adapter.
3 Remove shaft adapter ring, 1C9613P04, from rear drive adapter.
Change 6 11
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Figure 4. LPT Module Strongback Fixture, 1C9613
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CAUTION
Do not allow the weight of the strongback to rest on the outer seal
carrier or shaft adapter ring after removing strongback retaining
screws.
4 Remove screws that secure strongback onto outer seal carrier.
5 Move strongback fixture, 1C9613, aft and separate from LPT module.
C. If LPT module will not be installed in shipping container, prepare shipping container
for storage as follows:
(1) Install support plate and 12 clamps into shipping container and secure to
mounting with 16 capscrews, washers, and nuts.
(2) Store pivot braces in corner of shipping container and secure with four capscrews,
washers, and nuts.
(3) Install top per paragraph 7, step D.
7. LPT Module Installation into Shipping Container.
A. Identify LPT module shipping container as follows:
(1) Obtain LPT module serial number (S/N) from 6:00 o'clock position on LPT
forward flange.
(2) Paint S/N on shipping container base. Ensure old S/N is completely obscured and
new S/N is legible.
(3) Ensure all shear mounts are secured at each of the shipping container corners.
NOTE
If LPT module is being removed from engine and installed directly
into container skip step B and proceed to step C.
B. If LPT module is installed in horizontal storage dolly, install strongback fixture,
1C9328, and adjustable CG fixture, 1C9330, per WP 2710 00.
(1) Remove restrain fixture, 1C9338, from module forward flange, figure 3.
(2) Remove quick-release pins securing LPT module to dolly.
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WARNING
Use correct lifting equipment and techniques. Stay out from under sus-
pended loads to prevent injury.
(3) Raise LPT module off dolly.
(4) Remove adapter plate, 1C9326P03, from LPT case forward flange.
C. Install LPT module into shipping container as follows:
(1) If support plate is not already installed in clevis mounts, remove 16 capscrews, nuts, and
washers that secure support plate onto mounting frame. Remove support plate and 12
clamps from shipping container, install in clevis mounts, and secure with two quick-
release pins.
(2) Install support plate onto LPT case forward flange as follows:
(a) Loosen 24 capscrews and retract 12 clamps on support plate.
(b) Slowly slide module toward support plate until forward flange contacts support
plate. Position support plate onto LPT case forward flange aligning 3 locating pins
and TOP VERTICAL mark on support plate with 12:00 o’clock position of LPT
module.
(c) Slide 12 clamps back into position over LPT case forward flange, clamps have
notches for 3 locating pins. Tighten 24 capscrews.
NOTE
This LPT module requires both top and bottom pivot braces. Ensure braces
are bolted together.
(3) Install both pivot braces in center of mounting frame by engaging pins in brace in holes
in frame. Secure pivot brace onto frame using two bolts and nuts at curved ends.
(4) Slowly lower LPT module in clevis mounts until strongback fixture, 1C9613, rests on
pivot brace located in center of shipping container.
(5) Remove adjustable CG lift fixture, 1C9627, from strongback fixture, 1C9613.
(6) Install two-legged sling onto strongback fixture, 1C9613, and connect hoist to sling.
Remove slack from sling.
(7) Lift LPT module and rotate in clevis mounts to forward end down position.
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(8) Remove pivot braces from center of mounting frame and store in corner of
container. Secure pivot brace to container with four capscrews, washers, and nuts.
NOTE
Ensure extension is installed on center shaft restraint.
(9) Install center shaft restraint to center of mounting frame, view B. Secure with four
capscrews and lockwashers. Tighten capscrews.
WARNING
Use correct lifting equipment and techniques. Stay out from under sus-
pended loads to prevent injury.
(10) Remove quick-release pins from clevis mounts and lift LPT module from clevis mounts.
(11) Align TOP VERTICAL markings of support plate on LPT module and marking on
mounting frame.
CAUTION
Ensure module is centered over shaft restraint in center of module.
ensure honeycomb seal at front of LPT module does not contact the shaft
restraint when LPT module is installed. Damage to seal may occur.
(12) Slowly lower LPT module and engage rotor shaft and center shaft restraint. Continue to
lower module until seated on restraint and two locating pins are aligned with holes in
adapter plate.
(13) Secure support plate onto mounting frame with 16 capscrews, washers, and nuts, sheet 1.
Tighten nuts.
(14) Remove strongback fixture, 1C9613, from LPT module per WP 2710 00
(15) Install shaft restraint lock through center of LPT shaft and thread into center shaft
restraint until tight.
D. Install top on shipping container as follows (figure 1):
(1) Raise four corner alignment tubes and secure into position with pins.
(2) Fill desiccant container, as required.
(3) Ensure flange and gasket on shipping container base are clean and serviceable.
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NOTE
Ensure tee-head bolts are aligned in recess before installing the lid
on the shipping container.
(4) Attach 2-ton (1,815 kg) hoist and sling to four lifting rings on sides of top. Attach
two control lines to opposite ends of top.
WARNING
Use correct lifting equipment and techniques. Stay out from
under suspended loads to prevent injury.
(5) Lower top straight down over LPT module, aligning forward and aft guide pins.
Ensure flanges seat.
(6) Remove hoist, sling, and guide ropes.
(7) Rotate tee-head bolts, sheet 2, section A-A, until long side of bolthead is
perpendicular to flange. Tighten tee-head bolt nuts to 420-510 lb in.
(47.5-57.6 N·m) of torque.
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WP 4010 00
WP 4010 00
WORK PACKAGE
TECHNICAL PROCEDURES
GAS TURBINE INLET INSPECTION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 10
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 10 ...... 5
Alphabetical Index
Subject Page
Gas Turbine Inlet Inspection....................................................................................................... 3
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1. Introduction.
This work package contains instructions for inspecting the gas turbine inlet.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Borescope Inspection WP 4015 00
3. Support Equipment.
None required.
4. Consumable Material.
None required.
5. Expendable Material.
None required.
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6. Gas Turbine Inlet Inspection.
WARNING
• Gas turbine shall not be operating and shall be verified as
inoperable. If possible, lock out system so it cannot be rotated.
• A safety observer shall be stationed adjacent to the inlet access.
CAUTION
Empty pockets before entering inlet to ensure no loose objects are
left in the inlet.
A. Before accessing inlet, do the following:
(1) Verify gas turbine will be inoperable during inspection.
(2) Deactivate fire extinguishing system per packager's manual.
(3) Station safety observer adjacent to inlet access.
(4) Secure enclosure door so that it will remain open. Enclosure door shall remain
open.
B. Access inlet plenum through access hatch or inlet duct access per packager's manual.
NOTE
Some items in table 1 can be inspected only if the gas turbine is
removed. If the gas turbine is installed, inspection will be limited to
accessible items only.
C. Using bright light, visually inspect gas turbine inlet per table 1. See figures 1 and 2.
2
1
D. If evidence of foreign object damage (FOD) is found, perform borescope inspection of
low pressure compressor (LPC) and high pressure compressor (HPC) sections per
WP 4015 00.
CAUTION
All tools or maintenance items shall be accounted for upon
job completion, or damage to engine could result.
E. Before exiting the enclosure, perform a thorough, final inspection for possible foreign
objects.
F. Secure inlet duct access per packager's manual.
G. Activate the fire extinguishing system per packager's manual and close enclosure door.
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Figure 1. Gas Turbine Inlet Inspection
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Figure 2. LPC Rotor Blade Inspection Criteria
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Table 1. Gas Turbine Inlet Inspection
On-Site
On-Site Max Repairable On-Site
Inspect Max Serviceable Limits Limits Corrective Action
NOTE
Some of the following items can be inspected only if the gas turbine
is removed. If the gas turbine is installed, inspection will be limited
to accessible items only.
1. Inlet Duct or Bellmouth Assembly for:
a. Damage – – Refer to packager's
manual for limits and
corrective action
b. Plugged water- None allowed Any amount Remove contamina-
wash discharge tion per packager's
holes manual
c. Dirty airflow None allowed Any amount Wipe clean if inlet
path surfaces screen has been
removed
d. Loose installa- None allowed Any amount Tighten fasteners per
tion fasteners packager's manual
2. Centerbody Assembly for:
a. Cracks None allowed Not repairable Replace centerbody
b. Nicks and Any number, any Any number, 0.06 inch Blend to remove high
scratches length, 0.03 inch (1.52 mm) deep, metal
(0.76 mm) deep, 0.06 inch (1.52 mm)
0.03 inch (0.76 mm) wide, and 0.05 inch
wide, 1.0 inch (1.27 mm) long, pro-
(25.4 mm) separation vided none extend into
boltholes
c. Missing paint Any amount, if no Any amount Touch up paint
exposed parent metal
d. Dirty airflow None allowed Any amount Wipe clean if inlet
path surfaces screen has been
removed
e. Loose bolts None allowed Any amount Tighten bolts
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Table 1. Gas Turbine Inlet Inspection (Continued)
On-Site
On-Site Max Repairable On-Site
Inspect Max Serviceable Limits Limits Corrective Action
3. Inlet FOD Sock for:
a. Tears and holes None allowed Any amount Replace sock per
packager's manual
b. Build up of None allowed Any amount Clean
debris and
deposits
c. Coverage and No missing coverage Any amount Cover and secure sock
security of sock allowed across entire screen per
across entire No non-secure areas packager's manual
screen allowed
4. Inlet FOD Screen for:
a. Damage and - - Refer to packager's
corrosion manual for limits and
corrective action
b. Cracked, None allowed Any amount Replace screen per
broken, or packager's manual
missing pieces
c. Coverage and No missing coverage Any amount Cover and secure
security of allowed screen across entire
screen across No non-secure areas inlet area per
entire inlet area allowed packager's manual
5. Baffles for:
a. Cracks, tears, – – Refer to packager's
and damage manual for limits and
corrective action
b. Loose fasteners None allowed Any amount Tighten fasteners
c. Contact with None allowed Any amount Reposition baffles to
variable inlet provide proper
guide vane clearance per
(VIGV) case packager's manual
6. Seals for:
a. Cracks, tears, – – Refer to packager's
and damage manual for limits and
corrective action
Change 5 7
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4010 00
Table 1. Gas Turbine Inlet Inspection (Continued)
On-Site
On-Site Max Repairable On-Site
Inspect Max Serviceable Limits Limits Corrective Action
b. Loose None allowed Any amount Tighten fasteners
fasteners
7. LPC Inlet Temperature/Pressure (T2/P2) Sensor for:
a. Damage None allowed Not repairable Replace sensor
b. Security No looseness allowed Any amount Tighten connections/
fasteners
c. Obstructions None allowed Any amount Clear obstructions
d. Buildup of None allowed Any amount Wipe clean
deposits
NOTE
If VIGV installed, inspect per step 8. If inlet frame assembly
installed, inspect per step 9.
8. VIGV and Flaps for:
a. Cracks None allowed Not repairable Replace VIGV
assembly
b. Dents and nicks TBP TBP –
c. Deleted
d. Dirt, salt, or None allowed Any amount Wipe clean if
industrial accessible
deposits
8A.VIGV, PN L43403, Flaps for:
a. Radial (1) All flaps with (a) Any single flap (a) Inspect inner and
movement movement of 0.050 in. with movement greater outer cases for case rub
(1.27 mm) or less than 0.050 in. per step 8B
(1.27 mm) but less than
0.060 in. (1.52 mm)
(b) Any single flap with (b) Replace VIGV
movement greater than assembly or return to
0.060 in. (1.52 mm), Depot
not repairable
8 Change 5
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4010 00
Table 1. Gas Turbine Inlet Inspection (Continued)
On-Site
On-Site Max Repairable On-Site
Inspect Max Serviceable Limits Limits Corrective Action
8A.A VIGV, PN L43918, Flaps for:
a. Radial (1) All flaps with (a) Any single flap (a) Inspect inner and
movement movement of 0.030 in. with movement greater outer cases for case rub
(0.76 mm) or less than 0.030 in. per step 8B
(0.76 mm) but less than
0.050 in. (1.27 mm)
(b) Any single flap (b) Replace VIGV
with movement greater assembly or return to
than 0.050 in. Depot
(1.27 mm), not
repairable
8B. Inner and Outer Cases for:
a. Inner case rub 0.015 in. (0.38 mm) or Greater than 0.015 in. Replace VIGV
due to loose less deep (0.38 mm), not assembly or return to
flaps repairable Depot
b. Outer case rub 0.030 in. (0.76 mm) or Greater than 0.030 in. Replace VIGV
due to loose less deep (0.76 mm), not assembly or return to
flaps repairable Depot
9. Inlet Frame Assembly for:
a. Cracks None allowed Not repairable Replace VIGV
assembly
b. Dents and nicks TBP TBP –
c. Loose flap TBP TBP –
d. Dirt, salt, or None allowed Any amount Wipe clean if
industrial accessible
deposits
10. LPC Stage 0 Rotor Blades for (figure 2):
a. Cracks None allowed Not repairable Replace blade
b. Chips, crush, None allowed Not repairable Replace blade
nicks, dents,
and scratches
in root area
Change 5 9
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4010 00
Table 1. Gas Turbine Inlet Inspection (Continued)
On-Site
On-Site Max Repairable On-Site
Inspect Max Serviceable Limits Limits Corrective Action
c. Chips and Any number, 0.025 inch Not repairable Replace blade
crush in (0.6 mm) deep
leading and
trailing edges,
except root
area
d. Scratches on Any number, Not repairable Replace blade
leading and 0.005 inch (0.13 mm)
trailing edges, deep, 0.5 inch
except root (1.27 mm) long
area
e. Nicks and Any number, Not repairable Replace blade
dents on 0.005 inch (0.13 mm)
leading and deep, 0.125 inch
trailing edges, (3.1 mm) diameter
except root
area
f. Tip curl Not more than Not repairable Replace blade
0.25 inch (6.35 mm) of
original blade tip
width
g. Pits and Any number, Not repairable Replace blade
erosion, 0.005 inch (0.13 mm)
except in deep, any diameter, any
root area spacing
h. Dirt, salt, or None allowed Any amount Wipe clean if
industrial accessible
deposits
10 Change 5
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4011 00
4WP 4011 00
WORK PACKAGE
TECHNICAL PROCEDURES
EXTERNAL ENGINE CLEANING
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-3 ...... 0
4 Blank ...... 0
Alphabetical Index
Subject Page
External Engine Cleaning ........................................................................................................... 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4011 00
1. Introduction.
This work package contains instructions for cleaning the external engine surfaces.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Gas Turbine Water-Wash WP 4014 00
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
ARDROX 6322 Local Purchase
B&B 3100 Local Purchase
Isopropyl Alcohol Fed Spec TT-I-735
Monopropylene Glycol AMS 1424
RMC Turbine/Engine Cleaner (Rivenaes) Local Purchase
Rochem FYREWASH Local Purchase
5. Expendable Material.
None required.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4011 00
6. External Engine Cleaning.
WARNING
Serious injury can occur when applying hydraulic pressure.
Eye protection is required. Relieve pressure before discon-
necting lines and fittings.
NOTE
If available, portable steam cleaning equipment may be used.
A. Wash external engine and components with 50-60 gallons (189-227 liters) of clean
water using a flexible hose with adjustable spray nozzle. Maintain water pressure of
40-45 psi (276-310 kPa).
B. If water will not remove dirt, apply water-wash solution per WP 4014 00 and allow to
soak for 2 hours minimum. Flush with clean water.
C. Start engine and operate at idle speed 5 minutes to dry excessive water.
3/(4 Blank)
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
WP 4012 00
WORK PACKAGE
TECHNICAL PROCEDURES
GAS TURBINE EXTERNAL INSPECTION (VISUAL)
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 52
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 51 ...... 0
52 Blank . . . . . . 0
Alphabetical Index
Subject Page
Gas Turbine External Inspection (Visual)................................................................................... 3
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
1. Introduction.
A. This work package contains instructions for performing a visual external inspection of
LM6000 gas turbine.
B. Replace electrical leads and connecting tubes on gas turbine, as required, per
SWP 1913 03.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Variable Bypass Valve (VBV) System Check WP 1312 00
Variable Stator Vane (VSV) Rigging WP 1411 00
Variable Stator Vane (VSV) Stages 3 to 5 Bushing WP 1412 00
Replacement (High-Boss HPC Stator Case)
Low Pressure Turbine (LPT) Module External Tubing, Har- SWP 1913 03
nesses, and Clamping
High Pressure Compressor (HPC) Stator Vanes Replacement SWP 2412 00
Variable Stator Vane Off-Schedule Inspection WP 4028 00
High Pressure Compressor Stator Variable Geometry Stage 5 LM6000-IND-150
Connecting Link Rework (PA, PB, PC, and PD Models)
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Silicone Rubber Adhesive GE Spec A15F6B6
(RTV 106)
5. Expendable Material.
None required.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
6. Gas Turbine External Inspection (Visual).
A. Inspect tubing, hoses, and electrical harnesses per table 1.
Table 1. Tubing, Hoses, and Electrical Harnesses Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Tubing for:
a. Cracks or splits None allowed Not repairable Replace tube*
b. Wrinkles or 2.0 percent of tube OD Not repairable Replace tube*
kinks in bend
ID
c. Dents and flat Any amount of devia- Not repairable Replace tube*
areas tion from contour,
within 20 percent of
original tube OD
d. Nicks or scores Any number, Any amount, Blend to remove high
0.005 inch (0.12 mm) 0.010 inch (0.25 mm) metal. Contour smooth
deep deep and polish
e. Leaking fittings None allowed Any amount Light polishing of
or connectors entire sealing (mating)
surfaces to remove
scratches. Tighten or
replace tube per
SWP 1913 03
f. Loose fittings None allowed Any amount Tighten per
or connectors SWP 1913 03
g. Attaching None allowed Any amount Replace cushion
cushion clamps clamps
for inadequate
clamping
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 1. Tubing, Hoses, and Electrical Harnesses Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
2. Right- and Left-Hand Side Stage 8 LPT Cooling Air Tubes for:
a. Open cracks Determine length of Less than 100 hours Replace tube
with visible time engine has and continue engine
separation, mis- operated with loss of operation
alignment of cooling air
adjacent sur-
faces, or
missing
material result-
ing in loss of
cooling air
NOTE
Depending on situational circumstances, it may be possible to
provide an extension to the 100-hour limit on operation with rup-
tured LPT cooling tube. Provide to GE hour and cycle data on
operation of HPT stage 2 disk and LPT stage 1 and 2 disks (with
and without ruptured tube). GE will use this data to determine
whether engine removal and disk inspection, required as correc-
tive action for operation with ruptured tube for greater than 100
hours, can be postponed to coincide with scheduled maintenance
on HPT and LPT.
3. Greater than 100 hours Remove engine for
inspection of HPT
stage 2 disk and LPT
stage 1 and 2 disks
4. Hoses (except special hoses) for:
a. Broken braid 3 wires per plait (a Not repairable Replace hose
wires band of interwoven
wires) and no more
than 6 broken wires per
assembly
b. Crimps None allowed Not repairable Replace hose
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Table 1. Tubing, Hoses, and Electrical Harnesses Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Leaking fittings None allowed Any amount Light polishing of
or connectors entire sealing (mating)
surfaces to remove
scratches. Tighten or
replace assembly per
SWP 1913 03
d. Loose fittings None allowed Any amount Tighten per
or connectors SWP 1913 03
e. Attaching None allowed Any amount Replace cushion
cushion clamps clamps
for inadequate
clamping
5. Fuel Hoses (Natural Gas, Steam, and Primary/Secondary Fuel Supply Hoses) for:
NOTE
Special hoses are convoluted Inco 625, not rubber or Teflon.
a. Broken braid 3 wires per plait (a Not repairable Replace hose
wires band of interwoven
wires) and no more
than 6 broken wires per
assembly
b. Crimps None allowed Not repairable Replace hose
c. Leaking fuel None allowed Any amount Tighten bolts or
hose plate replace gasket
d. Loose fuel hose None allowed Any amount Tighten bolts
plate
e. Bulges None allowed Any amount Replace hose
6. Electrical Cables for:
a. Broken braid 50 percent of exterior Not repairable Replace assembly*
braid wires may be
broken, provided cir-
cuit continuity is main-
tained
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 1. Tubing, Hoses, and Electrical Harnesses Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Kinks/crimps Any amount, provided Not repairable Replace assembly*
circuit continuity is
maintained. Insulation
resistance pin-to-pin
and pin-to-shell shall
be 1 megohm mini-
mum
c. Security/ Clamps must be secure Any amount Correct as required
installation with no evidence of
abrasion. No relative
motion between cable
and supporting hard-
ware
d. Loose None allowed Any amount Hand-tighten connec-
electrical tor
connectors
e. Seal damaged None allowed Any amount Replace seal
or missing
f. Braid/ 50 percent of wires Not repairable Replace assembly*
connector must be secure and cir-
separation cuit continuity main-
tained
g. Bent or Must assemble to mat- Any amount Straighten pins or
distorted pins ing connector replace assembly*
h. Cracked or None allowed Not repairable Replace assembly*
broken pins
i. Corroded pins None allowed Not repairable Replace assembly*
j. Cracked inserts Any amount, provided Not repairable Replace assembly*
continuity is main-
tained. Insulation resis-
tance pin-to-pin and
pin-to-shell shall be
1.0 megohm min
k. Distorted Must assemble to mat- Not repairable Replace assembly*
inserts ing connector and seal
l. Right-Hand Side Upper and Lower Stage 11 HPT Cooling Air Tubes and Left-Hand
Side Upper and Lower Stage 11 HPT Cooling Air Tubes for:
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Table 1. Tubing, Hoses, and Electrical Harnesses Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
m. Open cracks or Determine length of Less than 100 hours Replace tube and con-
missing time engine has oper- tinue engine operation
material result- ated with loss of cool-
ing in loss of ing air
cooling air
n. Greater than 100 hours Remove engine for
inspection of stage 1
and stage 2 HPT disks
*Contact GE Marine and Industrial Customer Service for repair data.
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
B. Inspect variable inlet guide vane (VIGV) assembly per table 2 and figure 1.
Table 2. VIGV Assembly Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. VIGV Case or Inlet Frame for:
a. Cracks None allowed Not repairable Replace VIGV assembly
b. Nicks, gouges, TBP – –
and scratches
c. Dents Any number with a Any amount Replace VIGV assembly
smooth contour,
0.030 inch (0.76 mm)
deep
d. Damaged Any amount, if parent Up to 5.0 percent of Touch up anodic coating
anodic coating metal is not showing total surface, provid-
ing damage does not
extend into parent
metal
e. Flanges for None allowed Any amount Tighten or replace
broken, loose, damaged hardware
or missing
attaching
hardware
2. VIGV Actuator for:
a. Leakage None allowed Any amount Tighten or replace fitting
or replace preformed
packing
b. Security No looseness allowed Any amount Tighten or replace
attaching hardware
c. Damaged or None allowed Not repairable Replace rod-end bearing
worn rod-end
bearing
3. Actuator Support Brackets for:
a. Cracks None allowed Not repairable Replace bracket
b. Distorted or None allowed Not repairable Replace bracket
bent
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Table 2. VIGV Assembly Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
4. Actuation Brackets for:
a. Cracks None allowed Not repairable Replace bracket
b. Distorted or None allowed Not repairable Replace bracket
bent
c. Loose, None allowed Not repairable Replace bushings or
damaged, or bracket
missing
bushings
5. Actuation Ring for:
a. Cracks None allowed Not repairable Replace VIGV assembly
b. Nicks, gouges, TBP – –
scratches, and
dents
c. Distortion None allowed Not repairable Replace VIGV assembly
d. Loose, None allowed Any amount Replace VIGV assembly
damaged, or
missing
bushings
e. Damaged 0.50 inch (12.7 mm) by Any length, 0.250 inch Touch up anodic coating
anodic coating 0.020 inch (0.5 mm), if (6.35 mm) wide, not to
damage does not exceed 3.0 percent of
extend into parent total coated surface
metal
6. Actuator Rigging Bracket for:
a. Cracks None allowed Not repairable Replace bracket
b. Distortion or None allowed Not repairable Replace bracket
bent
c. Security No looseness allowed Any amount Tighten securing
hardware
7. Vane Lever Arms for:
a. Cracks None allowed Not repairable Replace VIGV assembly
b. Distorted or None allowed Not repairable Replace VIGV assembly
bent
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 2. VIGV Assembly Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Damaged or Bearing shall rotate Not repairable Replace VIGV assembly
bound bearing freely in all directions
under finger pressure
d. Security No looseness allowed Any amount Replace or tighten lock-
nut. Replace or tighten
actuation ring nut and
bolt
8. T2/P2 sensor for No looseness allowed Any amount Tighten attaching
security hardware
1
10
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Figure 1. VIGV Assembly
11
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
C. Inspect low pressure compressor (LPC) per table 3 and figure 2.
Table 3. LPC Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. LPC Stages 0-3 Case for:
a. Cracks other None allowed Not repairable Replace stages 0-3 stator
than boltholes case
b. Cracks at bolt- One, every tenth bolt- Not repairable Replace stages 0-3 stator
holes hole in each circumfer- case
ential flange,
0.250 inch (6.35 mm)
long. None allowed on
horizontal flanges
c. Nicks, scores, Any number, -- Blend to remove high
and scratches 0.050 inch (1.27 mm) metal. Contour smooth
deep, separated by and polish
0.250 inch (6.35 mm),
after removal of high
metal
d. Dents Any number with a -- Blend to remove high
smooth contour, metal. Contour smooth
0.060 inch (1.52 mm) and polish
deep
e. Missing Any amount -- --
anodize
f. Nicks, dents, None allowed Any amount Blend to remove high
scratches, or metal. Contour smooth
scores on and polish
mating flanges
or split-line
g. Loose or None allowed Any amount Replace bolts and nuts
missing bolts
and nuts
h. Loss of self- None allowed Any amount Replace nut
locking quality
of nuts
12
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Table 3. LPC Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
2. LPC Stage 4 Case for:
a. Cracks other None allowed Not repairable Replace stage 4 stator
than boltholes case
b. Cracks at One, every tenth bolt- Not repairable Replace stage 4 stator
boltholes hole in each circumfer- case
ential flange,
0.250 inch (6.35 mm)
long
c. Nicks and Any number, -- Blend to remove high
scratches 0.050 inch (1.27 mm) metal. Contour smooth
deep, after removal of and polish
high metal, with
0.250 inch (6.35 mm)
separation
d. Dents Any number with a -- Blend to remove high
smooth contour, metal. Contour smooth
0.060 inch (1.52 mm) and polish
deep
3. No. 1 Electrical Interface Panel for:
a. Cracks None allowed Any amount Replace panel
b. Nicks, Any amount, Defects not exceeding Blend to remove high
scratches, and 0.0050 inch (0.12 mm) 75 percent of sheet metal. Contour smooth
scores deep metal thickness and polish
c. Dents and dis- Any amount, if proper Any amount Re-form using hand
tortion assembly with mating tools. No cracks allowed
parts can be accom-
plished
d. Security No looseness allowed Any amount Tighten attaching bolts
per SWP 1913 03
13
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
2
Figure 2. LPC Case and Front Frame
D. Inspect air collector per table 4.
Table 4. Air Collector Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Aft Flange and Mounts for:
a. Cracks None allowed Not repairable Replace air collector*
b. Distortion None allowed Not repairable Replace air collector*
2. All Other Surfaces for:
a. Cracks Any number, Not repairable Replace air collector*
0.120 inch (3.04 mm)
long, separated by
2.0 inches (50.8 mm)
b. Distortion Any amount -- --
14
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Table 4. Air Collector Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Dents Any amount, 0.50 inch Any amount Re-form to original
(12.7 mm) deep, sepa- contour
rated by 4.0 inches
(101.6 mm), provided
there are no parent
cracks
d. Nicks or Any number, Any number Blend smooth and
scratches 0.030 inch (0.76 mm) touch up paint
deep, separated by
1.0 inch (25.4 mm). No
sharp grooves allowed
e. Corrosion None allowed Any amount Blend smooth and
touch up paint
f. Missing, None allowed Any amount Blend smooth and
chipped, or touch up paint
peeling paint
3. Frame Seals for:
a. Tears in rubber None allowed Not repairable Replace frame seal
b. Security No looseness allowed Any amount Tighten attaching
screws
4. Brackets for:
a. Cracks None allowed Not repairable Replace bracket
b. Loose, None allowed Any amount Replace rivet
damaged, or
missing rivets
c. Security No looseness allowed Any amount Tighten attaching hard-
ware per SWP 1913 03
* Contact GE Marine and Industrial Customer Service for repair data.
15
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
E. Inspect the front frame assembly per table 5 and figure 3.
Table 5. Front Frame Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Mounts and trun- None allowed Not repairable Replace part
nions for cracks
2. All Other Surfaces for:
a. Cracks TBP – –
b. Dents TBP – –
c. Nicks, gouges, TBP – –
and scratches
3. Threaded pads, None allowed One full thread Chase threads
ports, and bosses for cumulative or
damaged threads continuous may be
removed
OR
Any amount of thread Install Heli-Coil insert
damage
NOTE
Inspection of any VBV system actuation component requires that the
access doors be removed from the air collector assembly.
4. VBV Actuator for:
a. Leakage None allowed Any amount Replace packing,
tighten fitting, or
replace actuator
b. Security No looseness allowed Any amount Tighten attaching hard-
ware
5. VBV Actuator and Bypass Door Rod-End Bearings for:
a. Cracks None allowed Not repairable Replace rod-end bearing
b. Distorted or None allowed Not repairable Replace rod-end bearing
bent
c. Damaged or None allowed Not repairable Replace rod-end bearing
bound bearing
6. VBV Actuator and Bypass Door Clevis for:
a. Cracks None allowed Not repairable Replace clevis
16
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Table 5. Front Frame Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Distorted or None allowed Not repairable Replace clevis
bent
7. VBV Actuator and Bypass Door Bellcranks for:
a. Cracks None allowed Not repairable Replace bellcranks
b. Evidence of None allowed Any amount Correct as required
binding
c. Security No looseness allowed Any amount Correct as required
8. VBV Actuation Ring for:
a. Cracks None allowed Not repairable Replace ring
b. Nicks, gouges, TBP -- --
scratches, and
dents
c. Distortion None allowed Not repairable Replace ring
d. Security No looseness allowed Any amount Correct as required
e. Damaged or None allowed Any amount Replace insert
missing insert
9. VBV Bypass Door Hinges for:
a. Cracks None allowed Not repairable Replace hinge
b. Security No looseness allowed Any amount Correct as required
c. Damaged or None allowed Any amount Replace bushing
missing
bushings
10. VBV Bypass Valve Doors for:
a. Cracks None allowed Not repairable Replace door
b. Security No looseness allowed Any amount Correct as required
c. Loose, cracked, Any amount -- --
or missing seals
d. Evidence of None allowed Any amount Perform VBV system
binding or mis- check per WP 1312 00
alignment and correct as required
11. T25 sensor for No looseness allowed Any amount Tighten attaching bolts
security
17
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Figure 3. HPC Stator Case Inspection Areas
18
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F. Inspect transfer gearbox assembly (TGB) per table 6.
Table 6. TGB Assembly Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Transfer Gearbox for:
a. Cracks None allowed Not repairable Replace transfer gear-
box
b. Nicks, scores, Any number, any – –
or scratches on length, 0.030 inch
nonmachined (0.76 mm) deep
surfaces
c. Leaking plugs None allowed Any amount Tighten loose fittings
or fittings or replace damaged
seals
d. Missing or None allowed Any amount Replace lockwire
broken
lockwire
2. Gearbox-mounted Accessories for:
a. Security No looseness allowed Any amount Tighten attaching hard-
ware
b. Leakage Any amount Not repairable Replace accessory
3. Mount and Sway Links for:
a. Cracks None allowed Not repairable Replace mount or sway
link
b. Security No looseness allowed Any amount Correct as required
c. Bushings for None allowed Not repairable Replace bushings
wear
4. Studs for:
a. Thread damage None allowed Total of 3/4 of one full Remove damage with
thread may be removed fine file
b. Looseness None allowed Any amount Torque stud one turn. If
still not tight, replace
transfer gearbox
5. No. 2 Electrical Interface Panel for:
a. Cracks Not serviceable Any amount Replace panel
19
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 6. TGB Assembly Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Nicks, Any number, Defects not exceeding Blend to remove high
scratches, and 0.005 inch (0.13 mm) 75 percent of sheet metal. Contour smooth
sores deep metal thickness and polish
c. Dents and dis- Any number, provided Any amount Re-form using hand
tortion proper assembly with tools. No cracks
mating parts can be allowed
accomplished
d. Security No looseness allowed Any amount Tighten attaching hard-
ware per SWP 1913 03
G. Inspect high pressure compressor (HPC) case per table 7 and figures 3 and 4.
Table 7. HPC Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
NOTE
Hot spots and bulges indicate internal damage in that area. Assess
condition by borescope inspection.
1. Casing Skin for:
a. Nicks, gouges, Any number, Not repairable Replace case
scratches, and 0.0150 inch (0.38 mm)
dents deep, after removal of
high metal
b. Cracks None allowed Not repairable Replace case
c. Bulges None allowed Not repairable Replace case
d. Hot spots (dis- Serviceable if metal is Not repairable Replace case
coloration) not crazed and cracks
are not present
e. Grooves worn Any length, Not repairable Replace case
by actuation 0.0250 inch (0.63 mm)
ring spacers deep, after removal of
high metal
20
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WP 4012 00
Table 7. HPC Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
2. Stages 8 and 11 Manifolds for:
a. Cracks None allowed Not repairable Replace case
b. Dents Any number, Not repairable Replace case
0.250 inch (6.35 mm)
deep, provided there is
a 0.0250 inch
(0.63 mm) minimum
radius at bottom of
dent
c. Nicks and Any number, Not repairable Replace case
scratches 0.010 inch (0.25 mm)
deep
3. Casing Ribs for:
a. Cracks None allowed Any amount removable Blend max depth flush
by blending flush with to case OD, min radius
casing skin equal to depth
b. Nicks, gouges, Any number, Not repairable Replace case
and scratches 0.060 inch (1.52 mm)
deep, 0.50 inch
(12 mm) long, with a
min separation of
2 inches (50.8 mm),
after removal of high
metal
4. Circumferential Flanges for:
a. Cracks
(1) Radially One per hole, maxi- Not repairable Replace case
outward mum 3 holes per flange
from bolt-
holes
(2) Bolthole to None allowed Not repairable Replace case
skin
21
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 7. HPC Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
(3) Cracks in None allowed Not repairable Replace case
fillet
between aft
circumfer-
ential
flange and
horizontal
flange
(4) All other None allowed Not repairable Replace case
areas
b. Nicks, Any number, Not repairable Replace case
scratches, and 0.030 inch (0.76 mm)
gouges deep, after removal of
high metal, provided
defect does not extend
completely across mat-
ing surface
5. Horizontal Flanges for:
a. Cracks None allowed Not repairable Replace case
b. Nicks, Any number, Not repairable Replace case
scratches, and 0.030 inch (0.76 mm)
gouges deep, after removal of
high metal, provided
defect does not extend
completely across mat-
ing surface
6. Horizontal flange None allowed Any amount Replace all loose, bro-
for bolts and nuts, ken, or missing
broken, loose, or bolts/nuts plus adja-
missing cent bolts/nuts
7. Circumferential None allowed Any amount Replace broken, loose,
flange for bolts and or missing bolts and
nuts, broken, loose, nuts
or missing
8. No. 3 Electrical Interface Panel for:
a. Cracks None allowed Any amount Replace panel
22
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Table 7. HPC Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Nicks, Any number, Defects not exceeding Blend to remove high
scratches, and 0.0050 inch (0.12 mm) 75 percent of sheet metal. Contour smooth
scores deep metal thickness and polish
c. Dents and dis- Any amount, provided Any amount Re-form using hand
tortion proper assembly with tools. No cracks
mating parts can be allowed
accomplished
d. Security No looseness allowed Any amount Tighten attaching bolts
per SWP 1913 03
4
23
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Figure 4. HPC Stator Case Crack Inspection
24
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GE Industrial AeroDerivative Gas Turbines Volume II
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H. Inspect variable stator vane (VSV) actuation components per table 8 and figure 5.
Table 8. VSV Actuation System Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. VSV Actuator for:
a. Leakage None allowed Any amount Tighten fitting or replace
fitting, packing, or actua-
tor
b. Security No looseness allowed Any amount Tighten attaching hard-
ware or replace parts
2. Actuator Bracket for:
a. Security No looseness allowed Any amount Tighten mounting bolts
b. Cracks None allowed Not repairable Replace bracket
c. Distortion None allowed Not repairable Replace bracket
3. Actuator lever None allowed Not repairable Replace guide and
guide for binding bracket, as required
or looseness
4. Actuation Lever Assembly for:
a. Security No looseness allowed Any amount Tighten attaching hard-
ware
b. Cracks None allowed Not repairable Replace lever assembly
c. Worn slot- None allowed Not repairable Replace bearing ball or
loaded bearings lever assembly
d. Seal boots for None allowed Not repairable Replace seal boot
wear
(tears/rips)
5. Actuation Lever Mount for:
a. Cracks None allowed Not repairable Replace mount
b. Bent stud None allowed Not repairable Replace mount
6. Clevis/Push Rod Assembly for:
a. Missing safety None allowed Any amount Replace safety wire
wire
b. Cracks None allowed Not repairable Replace part
25
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 8. VSV Actuation System Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Bending None allowed Not repairable Replace part. Perform
VSV off-schedule inspec-
tion per WP 4028 00
7. Rod-End Bearings for:
a. Cracks None allowed Not repairable Replace rod-end bearing.
Perform VSV off-sched-
ule inspection per
WP 4028 00
b. Bending None allowed Not repairable Replace rod end bearing.
Perform VSV off-sched-
ule inspection per
WP 4028 00
c. Looseness or None allowed Not repairable Replace rod-end bearing
surface wear
8. Connecting Link for:
a. Cracks None allowed Not repairable Replace connecting link.
Perform VSV off-sched-
ule inspection per
WP 4028 00
b. Lever arm hole None allowed Not repairable Replace connecting link
wear
c. Loose bolts None allowed Any amount Replace bolt or actuation
ring
d. Broken or dis- None allowed Not repairable Replace connecting link.
torted Perform VSV off-sched-
ule inspection per
WP 4028 00
9. Actuation Ring for:
a. racks None allowed Not repairable Replace actuation ring.
Perform VSV off-sched-
ule inspection per
WP 4028 00
b. Broken or None allowed Not repairable Replace actuation ring.
distorted Perform VSV off-sched-
ule inspection per
WP 4028 00
26
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Table 8. VSV Actuation System Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Improperly None allowed Any amount Adjust spacer clearance
adjusted per WP 1411 00
spacers
d. Loose spacer None allowed One per ring segment Apply silicone rubber
nuts (stage 5 compound around nut,
only) back off spacer until head
is against ring, tighten
locknut to secure
e. Actuation ring None allowed Not repairable Replace sleeve
sleeve torn or
with missing
pieces
f. Worn or elon- None allowed Not repairable Replace actuation ring.
gated lever arm Perform VSV off-sched-
pin hole ule inspection per
WP 4028 00
10. Vane Lever Arms for:
a. Security No looseness allowed. Locknut in place Replace vane or locknut
Locknut shall be tight
with at least one vane
stud thread showing
Locknut missing Replace locknut. Perform
VSV off-schedule inspec-
tion per WP 4028 00
b. Cracks, distor- None allowed Not repairable Replace lever arm. Per-
tion, bending, form VSV off-schedule
or loose pin inspection per
WP 4028 00
c. Rub marks or None allowed Not repairable Replace lever arm.
scratching of Re-work connecting link
lever arm from per Service Bulletin
contact with LM6000-IND-150
connecting link
27
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 8. VSV Actuation System Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
11. Vane Radial Assembly, IGV-Stage 2, for:
a. Radial outward Any amount less than -- Continue operation
movement (pull 0.020 inch (0.51 mm)
vane stem out, indicating inner bush-
away from HPC ing wear. No visible
case, and bushings or washers
measure using missing (whole or in
shim gages or part). No metal-to-
with dial indi- metal contact
cator on top of
vane stem)
b. radial outward Any amount between -- Plan for washer and bush-
movement (pull 0.020 inch (0.51 mm) ing replacement at next
vane stem out, and 0.025 inch maintenance interval per
away from HPC (0.64 mm). No visible WP 2412 00
case, and bushings or washers
measure using missing (whole or in
shim gages or part). No metal-to-
with dial indi- metal contact
cator on top of
vane stem)
c. Radial outward Any amount less than Not repairable Replace inner and outer
movement (pull 0.025 inch (0.64 mm). bushings per WP 2412 00
vane stem out, No visible bushings or
away from HPC washers missing
case, and (whole or in part). No
measure using metal-to-metal contact
shim gages or
with dial indi-
cator on top of
vane stem)
d. Side-to-side Any amount, provided Not repairable Replace inner and outer
movement bushings or washers bushings per WP 2412 00
(vane stem are not missing (whole
wiggle, or in part). No metal-
side-to-side, to-metal contact
perpendicular
to lever arm)
28
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WP 4012 00
Table 8. VSV Actuation System Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
e. Misassembled, None allowed Not repairable Perform VSV off-
cocked, bent, or schedule inspection per
broken lever WP 4028 00 and resulting
arms or maintenance actions.
actuation arm Replace lever arms and
sleeves actuation arm sleeves per
WP 2412 00
f. Lever arm None allowed Not repairable Replace nuts. Ensure
locknuts backed proper torque value on all
off, not other nuts per
clamping lever WP 2412 00
arm
12. Vane Assembly, Stages 3 and 4, for:
NOTE
Before Service Bulletin LM6000-IND-213, stage 3-5 bushings have
an integrally molded bushing in a metal housing. After Service Bulle-
tin LM6000-IND-213 there is a metal housing and a separable
washer and bushing. The housing should be reusable.
a. Radial outward Any amount less than -- Continue operation
movement (pull 0.030 inch (0.76 mm)
vane stem out, indicating inner
away from HPC bushing wear. No
case, and visible bushings or
measure using washers missing
shim gages or (whole or in part). No
with dial indi- metal-to-metal contact
cator on top of
vane stem)
29
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 8. VSV Actuation System Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. b. Radial Any amount between -- Plan for bushing and or
outward 0.030 inch (0.76 mm) washer after Service Bul-
movement (pull and 0.040 inch letin LM6000-IND-213
vane stem out, (1.02 mm), no replacement at next main-
away from HPC visible bushings or tenance interval
case, and washers missing per WP 1412 00 or
measure using (whole or in part). No WP 2412 00
shim gages or metal-to-metal contact
with dial indi-
cator on top of
vane stem)
c. c. Radial Any amount less than Not repairable Replace inner and outer
outward 0.040 inch (1.02 mm), bushings and or washers
movement (pull no visible bushings or after Service Bulletin
vane stem out, washers missing LM6000-IND-213
away from HPC (whole or in part). No per WP 1412 00 or WP
case, and metal-to-metal contact 2412 00
measure using
shim gages or
with dial indi-
cator on top of
vane stem)
d. d. Bushing for Less than 12,500 hours Any amount greater Replace bushings and or
time since than 12,500 hours washers after Service Bul-
installation letin LM6000-IND-213
per WP 1412 00 or
WP 2412 00
e. e. Side-to-side Any amount, provided Not repairable Replace bushings and or
movement bushings or washers washers after Service Bul-
(vane stem are not missing (whole letin LM6000-IND-213
wiggle, or in part). No metal- per WP 1412 00 or
side-to-side, to-metal contact WP 2412 00
perpendicular
to lever arm)
30
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WP 4012 00
Table 8. VSV Actuation System Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
f. Misassembled, None allowed Not repairable Perform VSV off-
cocked, bent, or schedule inspection per
broken lever WP 4028 00 and resulting
arms or actua- maintenance actions.
tion arm sleeves Replace lever arms and
actuation arm sleeves per
WP 1412 00 or
WP 2412 00
g. Lever arm None allowed Not repairable Replace locknuts. Ensure
locknuts backed proper torque value on all
off, not other nuts per
clamping lever WP 1412 00 or
arm WP 2412 00
13. Vane Assembly, Stage 5, for:
NOTE
Before Service Bulletin LM6000-IND-213, stage 3-5 bushings have
an integrally molded bushing in a metal housing. After Service Bulle-
tin LM6000-IND-213 there is a metal housing and a separable
washer and bushing. The housing should be reusable.
a. Radial outward Any amount less than -- Continue operation
movement (pull 0.025 inch (0.64 mm)
vane stem out, indicating inner
away from HPC bushing wear, no
case, and visible bushings or
measure using washers missing
shim gages) (whole or in part). No
metal-to-metal contact
b. Radial outward Any amount between -- Plan for bushings and or
movement (pull 0.025 inch (0.64 mm) washers after Service Bul-
vane stem out, and 0.035 inch letin LM6000-IND-213
away from HPC (0.89 mm), no visible replacement at next main-
case, and bushings or washers tenance interval per
measure using missing (whole or in WP 1412 00 or
shim gages) part). No metal-to- WP 2412 00
metal contact
31
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 8. VSV Actuation System Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Radial outward Any amount less than Not repairable Replace inner and outer
movement (pull 0.035 inch (0.89 mm), bushings and or washers
vane stem out, no visible bushings or after Service Bulletin
away from HPC washers missing LM6000-IND-213 per
case, and (whole or in part). No WP 1412 00 or
measure using metal-to-metal contact WP 2412 00
shim gages)
d. Side-to-side As measured with dial – Continue operation
movement indicator, less than
(vane stem 0.020 inch (0.51 mm)
wiggle in either direction
side-to-side
perpendicular
to lever arm
using dial indi-
cator located on
nut surface
touching top of
lever arm)
e. Bushing for Less than 12,500 hours Any amount greater Replace bushings and or
time since than 12,500 hours washers after Service Bul-
installation letin LM6000-IND-213
per WP 1412 00 or
WP 2412 00
f. Side-to-side As measured with dial Not repairable Plan for bushing
movement indicator, amount replacement as soon as
(vane stem between 0.020 inch practical, not to exceed
wiggle (0.51 mm) and next periodic inspection
side-to-side 0.035 inch (0.89 mm)
perpendicular in either direction
to lever arm
using dial indi-
cator located on
nut surface
touching top of
lever arm)
32
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WP 4012 00
Table 8. VSV Actuation System Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
g. Side-to-side As measured with dial Not repairable Replace bushings and or
movement indicator, amount washers after Service Bul-
(vane stem under 0.035 inch letin LM6000-IND-213
wiggle (0.89 mm) per WP 1412 00 or
side-to-side WP 2412 00 prior to
perpendicular continued operation
to lever arm
using dial
indicator
located on nut
surface
touching top of
lever arm)
h. Lever arm At bushing replace- Not repairable Replace lever arm per
inspection at ment per any condition, WP 1412 00 or
bushing look for evidence of WP 2412 00
replacement any exposed metal
when replacing
bushing
i. Misassembled, None allowed Not repairable Perform VSV off-
cocked, bent, or schedule inspection
broken lever per WP 4028 00 and
arms or resulting maintenance
actuation arm actions. Replace lever
sleeves arms and actuation arm
sleeves per WP 1412 00
or WP 2412 00
j. Lever arm None allowed Not repairable Replace nuts. Ensure
locknuts backed proper torque value on all
off, not other nuts per
clamping lever WP 1412 00 or
arm WP 2412 00
33
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 8. VSV Actuation System Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
14. Vane Bushings or housings, Stages 3-5 for:
a. Looseness Bushings must be Any amount Tighten bolt, not to
using finger tightly clamped to case exceed torque value spec-
pressure, and ified per WP 2412 00.
side-to-side or Ensure bolthole and bush-
fore and aft ing mating surface with
wiggle motion, case are free of obstruc-
any amount. tions
Bushing or
housings bolts
not seated
(clamping
bushing).
Shim-check
bushing or bolt
if suspected
loose
5
34
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WP 4012 00
Figure 5. VSV System Inspection
35
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WP 4012 00
I. Inspect fuel manifold per table 9.
Table 9. Fuel Manifold Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Fuel Manifold for:
a. Cracks None allowed Not repairable Replace manifold
segment
b. Nicks, scores, – – –
and scratches
c. Leaks between None allowed Any amount Tighten bolts or replace
segments gasket
d. Leaking fuel None allowed Any amount Tighten bolts or replace
hose plate gasket
e. Loose fuel hose None allowed Any amount Tighten bolts
plate
J. Inspect compressor rear frame (CRF) per table 10 and figure 6.
Table 10. CRF Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. CRF Outer Casing for:
a. Cracks in None allowed Not repairable Replace engine
parent metal
b. Cracks in welds Any number, separated Not repairable Replace engine
by 0.50 inch (12.7 mm),
0.10 inch (2.54 mm) long
transverse to the weld,
and 0.060 inch
(1.52 mm) long longitu-
dinal to weld
36
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4012 00
Table 10. CRF Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Nicks, scores, In axial direction, any Any number Blend out over a
and scratches number, 0.0150 inch 0.50 inch (12.7 mm)
(0.38 mm) deep and radius
1.0 inch (25.4 mm) long.
In circumferential direc-
tion, any number,
0.030 inch (0.76 mm)
deep and 1.0 inch
(25.4 mm) long with a
min separation of
1.0 inch (25.4 mm) after
removal of high metal,
provided metal is not
reduced to less than 75
percent of original thick-
ness
d. Dents, Any number with a Not repairable Replace engine
distortions, or smooth contour, devia-
waviness tions within 0.250 inch
(6.35 mm) of normal sur-
face contour, except on
mating (sealing) surfaces
e. Hot spots Any number, provided Not repairable Replace engine
(discoloration) metal is not crazed
f. Bulges Not serviceable when Not repairable Replace engine
associated with heat dis-
coloration
2. Fuel Nozzle Pad and Igniter Pad Areas for:
a. Cracks None allowed Not repairable Replace engine
b. Damaged None allowed One full thread may be Chase threads or install
threads removed, if remaining Heli-Coil insert
threads are not dam-
aged
c. Fuel nozzle pad None allowed Not repairable Replace engine
burn through
caused by failed
nozzle
37
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4012 00
Table 10. CRF Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
3. All Other Pads and Threaded Parts for:
a. Nicks, scores, Any number, 0.030 inch Not repairable Replace engine
and scratches (0.76 mm) deep not
extending across more
than 1/2 a sealing sur-
face, after removal of
high metal. No air leak-
age allowed
b. Thread damage None allowed One full thread may be Chase threads or install
removed, if remaining Heli-Coil insert
threads are not dam-
aged
4. CRF Forward Flange for:
a. Bolthole cracks Not serviceable Not repairable Replace engine
b. Nicks, scores, Any number, any length, Not repairable Replace engine
and scratches 0.030 inch (0.76 mm)
deep, after removal of
high metal, that do not
extend across more than
0.750 inch (19.05 mm) of
flange sealing lip
5. CRF Rear Flange for:
a. Bolthole radial One per hole, four per Not repairable Replace engine
cracks flange, radially outward
only
b. Wear on Any amount, provided Not repairable Replace engine
forward face bolthead completely cov-
around bolthole ers hole to seal air leak-
age. Maximum of two
non-adjacent hole loca-
tions allowed
38
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WP 4012 00
Table 10. CRF Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Nicks, scores, Any number, any length, Not repairable Replace engine
and scratches 0.030 inch (0.76 mm)
deep, after removal of
high metal, that does not
extend across more than
0.750 inch (19.05 mm) of
flange sealing lip
6. Oil Supply, Oil Scavenge, Sump Vent, and Sump Pressurizing Tubes for:
a. Cracks Not serviceable Not repairable Replace engine
b. Nicks, scores, Any number, 0.0050 inch Not repairable Replace engine
and scratches (0.12 mm) deep, after
removal of high metal
c. Wear at contact Not serviceable Not repairable Replace engine
point of strut
pad
d. Dents Any number with a Not repairable Replace engine
smooth contour,
0.250 inch (6.35 mm)
deep, except on mating
(sealing) surfaces
e. Oil supply Any amount, 0.0050 inch Not repairable Replace engine
tube grooving (0.12 mm) deep, after
and wear on removal of high metal
sleeve
f. Scavenge tubes Any amount, 0.0050 inch Not repairable Replace engine
grooving and (0.12 mm) deep, after
wear on sleeves removal of high metal
g. Vent tube Any amount, 0.020 inch Not repairable Replace engine
grooving and (0.50 mm) deep, after
wear on sleeves removal of high metal
h. Vent tube 50 percent of sump vent Not repairable Replace engine
coking tube opening may be
blocked off by coking as
determined visually by
looking into outer end of
strut tubes
39
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WP 4012 00
Table 10. CRF Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
i. Sump pressur- Any amount, 0.0050 inch Not repairable Replace engine
ization tube (0.12 mm) deep, after
grooving and removal of high metal
wear on sleeves
7. All Other CRF Tubes for:
a. Cracks None allowed Not repairable Replace engine
b. Nicks and Any number, any length, Not repairable Replace engine
scratches 0.010 inch (0.25 mm)
deep, after removal of
high metal
c. Dents Any number, 1/5 tube Any number Re-form to original
diameter, provided contour. Inspect for
proper assembly can be cracks
obtained
d. Bent (out of Not serviceable Any amount Straighten tube. Inspect
alignment) for cracks
6
40
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Figure 6. CRF Inspection
41
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WP 4012 00
K. Inspect high pressure turbine (HPT) per table 11 and figure 7.
Table 11. HPT Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. HPT Case (Nozzle Stator Support) for:
a. Cracks Not serviceable Not repairable Replace HPT stage 2
nozzle assembly
b. Nicks and Any number, any Any number, any Blend to remove high
scratches length, 0.0150 inch length, provided the metal. Contour smooth
(0.38 mm) deep, afterthickness of parent and polish
removal of high metalmetal is not reduced
more than 0.0150 inch
(0.38 mm), after
removal of high metal
and blending
c. Dents or bulges Three dents or bulges, Not repairable Replace HPT stage 2
0.50 inch (12.7 mm) nozzle assembly
diameter, 0.120 inch
(3.05 mm) deep. No
high metal allowed on
flange mating surfaces
2. Flanges for:
a. Cracks from Four cracks radially Not repairable Replace HPT stage 2
boltholes outward, provided nozzle assembly
effected holes are sepa-
rated by five boltholes.
None radially inward
b. Nicks and Any number, any Any number, any Blend to remove high
scratches length, 0.0150 inch length, provided the metal. Contour smooth
(0.38 mm) deep, after thickness of parent and polish
removal of high metal metal is not reduced
more than 0.0150 inch
(0.38 mm), after
removal of high metal
and blending
42
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Table 11. HPT Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Broken, loose, None allowed Any amount Tighten or replace
or missing damaged hardware
attaching
hardware
3. Borescope ports for None allowed One full thread may be Chase threads or
damaged threads removed or missing replace Heli-Coil insert
4. Air Tubes for:
a. Cracks None allowed Not repairable Replace HPT stage 2
nozzle assembly
b. Dents TBP – –
* Contact GE Marine and Industrial Customer Service for repair data.
7
43
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Figure 7. HPT Case Inspection
L. Inspect low pressure turbine (LPT) per table 12 and figure 8.
Table 12. LPT Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. LPT Case for:
a. Cracks None allowed Not repairable Replace LPT module
b. Nicks Any number, Not repairable Replace LPT module
0.0150 inch (0.38 mm)
deep, after removal of
high metal
44
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WP 4012 00
Table 12. LPT Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Scratches and Any number, Not repairable Replace LPT module
scores 0.010 inch (0.25 mm)
deep (after removal of
high metal) in axial
direction. Any num-
ber, 0.010 inch
(0.25 mm) deep (after
removal of high metal),
1.0 inch (25.4 mm)
separation, in circum-
ferential direction
d. Dents Any number with a Not repairable Replace LPT module
smooth contour,
0.1250 inch (3.18 mm)
deep, provided assem-
bly can be accom-
plished
e. Distortion None allowed Not repairable Replace LPT module
f. Penetration None allowed Not repairable Replace LPT module
g. Cracks in None allowed Not repairable Replace LPT module
bosses
h. Damaged None allowed Any number Chase threads or install
threads in Heli-Coil insert
bosses
i. Hot spots Any amount, provided Not repairable Replace LPT module
(distortion) metal is not granular
and cracks are not
present
j. Heat or other Any amount, provided Not repairable Replace LPT module
discoloration there are no associated
distortion bulges
k. Bulges Any amount not asso- Not repairable Replace LPT module
ciated with heat discol-
oration and provided
proper assembly can be
accomplished
2. Forward and Aft Flanges for:
45
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WP 4012 00
Table 12. LPT Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
a. Cracks None allowed Not repairable Replace LPT module
b. Nicks, scores, Any number, any Not repairable Replace LPT module
and scratches length, 0.030 inch
(0.76 mm) deep, after
removal of high metal
with 1.0 inch
(25.4 mm) separation
c. Dents Any number, provided Not repairable Replace LPT module
damage does not
extend across more
than 3/4 of flange face
and does not result in
flange distortion
d. Broken, loose, None allowed Any amount correct- Tighten or replace
or missing able by replacing or damaged hardware
attaching tightening
hardware
3. Borescope ports for None allowed One full thread may be Chase threads or install
damaged threads removed or missing Heli-Coil insert
4. Air Manifold for:
a. Security No looseness allowed Any amount Correct as required
b. Cracks None allowed Not repairable Replace manifold
c. Dents and flat Any amount within 20 Not repairable Replace manifold
areas percent of original tube
OD
d. Nicks and Any amount, Any amount, Blend to remove high
scores 0.0050 inch (0.12 mm) 0.010 inch (0.26 mm) metal. Contour smooth
deep deep and polish
5. Support Links for:
a. Security No looseness allowed Any amount Correct as required
b. Broken safety None allowed Any amount Replace safety wire
wire
c. Cracks None allowed Not repairable Replace link
46
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Table 12. LPT Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
d. Distortion Any amount, provid- Not repairable Replace link
(bending) ing parts are not under
stress or contacting sur-
rounding hardware
6. Support Link Brackets for:
a. Security No looseness allowed Any amount Tighten or replace
hardware
b. Cracks None allowed Not repairable Replace bracket
c. Distortion Any amount, provid- Not repairable Replace bracket
ing parts are not under
stress or contacting sur-
rounding hardware
d. Worn bushings 0.060 inch (1.52 mm) Not repairable Replace bracket
wear permitted
7. T48 Thermocouples for:
a. Security No looseness allowed Any amount Tighten or replace
hardware
b. Loose KN/KP No looseness allowed Any amount Replace T48 harness
studs or thermocouple as
required
8. P48 probe for secu- No looseness allowed Any amount Tighten bolts
rity
9. No. 4 Electrical Interface Panel for:
a. Cracks None allowed Any amount Replace panel
b. Nicks, Any amount, Defects not exceeding Blend to remove high
scratches, and 0.0050 inch (0.12 mm) 75 percent of sheet metal. Contour smooth
scores deep metal thickness and polish
c. Dents and dis- Any amount, provided Any amount Re-form using hand
tortion proper assembly with tools. No cracks
mating parts can be allowed
accomplished
d. Security No looseness allowed Any amount Tighten attaching bolts
per SWP 1913 03
8
47
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Figure 8. LPT Case and TRF Inspection
48
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M. Inspect turbine rear frame (TRF) per table 13 and figure 8.
Table 13. TRF Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Insulation Blankets for:
a. Tears (wire Any number, Not repairable Replace blanket
mesh and insu- 2.0 inches (50.8 mm)
lation material long with 8.0 inches
intact) (203.2 mm) separation
b. Wire mesh or None allowed Not repairable Replace blanket
insulation
material torn
c. Loose fasteners None allowed Any number Tighten or replace
safety wire
d. Reflective None allowed Not repairable Replace blanket
material burnt
away or
missing
e. Security No loose blankets Any amount Tighten or replace
allowed safety wire
f. Saturated with None allowed Not repairable Replace blanket
fuel or oil
2. Flanges for:
a. Cracks None allowed Not repairable Replace LPT module
b. Nicks, gouges, TBP – –
and scratches
c. Broken, loose, None allowed Any amount Tighten or replace
or missing damaged hardware
attaching
hardware
3. Mounts for cracks None allowed Not repairable Replace mounts
49
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Table 13. TRF Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
4. Strut Pads for:
a. Cracks Any amount in strut Not repairable Replace LPT module
ends that do not permit
air leakage. One bolt-
hole per flange may be
cracked through radi-
ally outward
b. Nicks and Any number, any Not repairable Replace LPT module
scratches length, 0.060 inch
(1.52 mm) deep, after
removal of high metal,
provided metal is not
reduced to less than 75
percent of its original
thickness
c. Dents Any number with a Not repairable Replace LPT module
smooth contour,
0.250 inch (6.35 mm)
deep, except on seal-
ing surfaces
5. All Other Surfaces for:
a. Cracks None allowed Not repairable Replace LPT module
b. Nicks, gouges, TBP – –
and scratches
6. Oil Supply and Scavenge Tubes for:
a. Cracks Not serviceable Not repairable Replace LPT module
b. Nicks, scores, Any number, Not repairable Replace LPT module
and scratches 0.0050 inch (0.12 mm)
deep, after removal of
high metal
c. Dents Any number with a Not repairable Replace LPT module
smooth contour,
0.250 inch (6.35 mm)
deep, except on mating
(sealing) surfaces
50
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Table 13. TRF Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
d. Tube wear Any amount, Not repairable Replace LPT module
sleeve for 0.0050 inch (0.12 mm)
grooving and deep, after removal of
wear high metal
51/(52 Blank)
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WP 4013 00
WORK PACKAGE
TECHNICAL PROCEDURES
GAS TURBINE EXHAUST SYSTEM INSPECTION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 1
6 Blank ...... 1
Alphabetical Index
Subject Page
Gas Turbine Exhaust System Inspection..................................................................................... 3
Change 1 1
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WP 4013 00
1. Introduction.
This work package contains instructions for inspecting the gas turbine exhaust system.
2. Reference Material.
None required.
3. Support Equipment.
None required.
4. Consumable Material.
None required.
5. Expendable Material.
Nomenclature Part No. Qty
Piston Ring, Outer L45063P16 1
Piston Ring, Outer L45063P13 ALT
Piston Ring, Inner L47833P01 1
Piston Ring, Inner L47833P02 ALT
2 Change 1
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WP 4013 00
6. Gas Turbine Exhaust System Inspection.
See figure 1.
1
WARNING
• Gas turbine shall not be operating and shall be verified as inop-
erable. If possible, lock out system so it cannot be rotated.
• The exhaust duct temperature shall be at an acceptable
working level, below 120°F (49°C). If exhaust parts are hot,
allow them to cool before inspection.
• A safety observer shall be stationed adjacent to the exhaust
duct access.
CAUTION
To ensure that no loose objects are left in the exhaust, empty pockets
before entering exhaust access.
A. Before accessing exhaust, do the following:
(1) Verify gas turbine will be inoperable during inspection.
(2) Deactivate fire extinguishing system per packager's manual.
(3) Station safety observer adjacent to exhaust duct access.
B. Access exhaust duct per packager's manual.
NOTE
Some items can only be inspected if the gas turbine and exhaust duct
are separated. If the gas turbine and exhaust duct are not separated,
inspection will be limited to accessible items only.
C. Using bright light, visually inspect turbine rear frame and inner and outer seal carriers
for cracks, security, metal deposits, and damage. Contact General Electric Marine and
Industrial Customer Service if discrepancies are found. See figure 1.
D. Using bright light, visually inspect exhaust duct, inner and outer diffuser walls, and
housings for cracks, security, metal deposits, and damage. If discrepancies are found,
refer to the packager's manual for limits and corrective action.
E. Using bright light, visually inspect inner and outer piston rings for wear and cracks
(figure 1). If rings are worn or cracked, replace rings.
Change 1 3
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Figure 1. Gas Turbine Exhaust Duct Interface
4 Change 1
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F. Perform thorough, final inspection of exhaust duct for possible foreign objects or tools
left in exhaust area.
G. Secure exhaust duct access per packager's manual.
H. Check exhaust system alignment as follows:
NOTE
Exhaust duct alignment should be checked after final full engine align-
ment is complete.
(1) Measure and record dimension A and dimension B at eight equally spaced locations
around circumference of exhaust duct. Calculate X as follows:
XA = AMAX - AMIN
(2) Refer to table 1 for the applicable limits. If dimensions exceed the table maximum
or minimum values, then adjust the exhaust diffuser. Refer to packager's manual.
Table 1. Exhaust System Limits
Minimum Maximum
Value Value Maximum XA
Dimension A 2.775 in. (70.49 mm) N/A 0.25 in. (6.35 mm)
(Measured at Outer Piston Ring)
Dimension B 0.14 in. (3.56 mm) N/A N/A
DIM A DIM B
1. 1.
2. 2.
3. 3.
4. 4.
5. 5.
6. 6.
7. 7.
8. 8.
AVG AVG
Change 1 5/(6 Blank)
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7WP 4014 00
WORK PACKAGE
TECHNICAL PROCEDURES
GAS TURBINE WATER-WASH
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 4
Alphabetical Index
Subject Page
Crank/Soak Cleaning .................................................................................................................. 4
On-Line Cleaning........................................................................................................................ 8
Water and Detergent Requirements............................................................................................. 3
Water-Wash Description ............................................................................................................. 3
Change 4 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4014 00
1. Introduction.
This work package contains instructions for performing water-wash procedures on the LM6000
gas turbine.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Water Purity - Compressor Cleaning Appendix A4
Liquid Detergent - Compressor Cleaning Appendix A5
System Descriptions Chapter 5
Engine Operation Chapter 8
Borescope Inspection WP 4015 00
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Acetone Fed Spec 0-A-51
ARDROX 6322 (solvent base) Local Purchase
CleanBladeTM GTC1000 Local Purchase
Conntect (water base) Local Purchase
Isopropyl Alcohol Fed Spec TT-I-735
Monopropylene Glycol AMS 1424
PROTOKLENZ-GT-SC Local Purchase
RMC Turbine/Engine Cleaner (solvent base) Local Purchase
Rochem FYREWASH (solvent base) Local Purchase
Techniclean GT (water base) Local Purchase
Turbotect 950 (water base) Local Purchase
Turbo-K Local Purchase
Zok 27 and Zok 27LA (water base) Local Purchase
5. Expendable Material.
None required.
2 Change 4
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6. Water-Wash Description.
NOTE
The need for gas turbine water wash and frequency is installation
and site specific. In particular, effectiveness of inlet filtration may
have a significant effect on need for washing. Reduced power out-
put and dirty appearance during borescope are indications that the
gas turbine may benefit from off-line water wash.
The following basic water-wash procedures may be applied:
A. Crank/Soak Cleaning: Applied while motoring the high pressure (HP) rotor at greater
than 2000 RPM and low pressure (LP) rotor at greater than 200 RPM. Used for
performing a thorough cleaning of engine. Crank-soak washing removes oily or tarry
deposits which bind dirt to blade. The frequency of wash must be tailored to type of
atmospheric contaminants, temperature, operational frequency/profile, gas turbine
health and site economics. In the absence of this information a prudent strategy would
be to crank-soak wash every 2 weeks.
B. On-line Cleaning: Applied while engine is running. Requires special on-line cleaning
manifold. It is used primarily to maintain gas turbine performance between crank-soak
washes but rarely is able to make a significant improvement in performance.
7. Water and Detergent Requirements.
A. Water quality and liquid detergent for crank/soak compressor cleaning must meet
requirements specified in Appendix A4 and Appendix A5,Volume I of this manual.
B. The liquid detergents listed below may be used for performing water-wash
procedures. Follow liquid detergent manufacturer's instructions for recommended
detergent/water dilution ratios. Ensure that detergents used, including those listed,
meet requirements specified by packager.
• ARDROX 6322 (solvent base)
• CleanBladeTM GTC1000
• Conntect (water base)
• PROTOKLENZ-GT-SC
• RMC Turbine/Engine Cleaner (solvent base)
• Rochem FYREWASH (solvent base)
• Techniclean GT (water base)
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• Turbotect 950 (water base)
• Turbo-K
• Zok 27 and Zok 27LA (water base)
C. In freezing weather, mix one of the antifreeze agents listed below with cleaning
solution. Refer to Appendix A5 for recommended solution mixtures and additional
information.
• Acetone
• Isopropyl alcohol
• Monopropylene Glycol
8. Crank/Soak Cleaning.
A. Before initiating crank/soak cleaning sequence, comply with the following
requirements:
WARNING
• The enclosure area shall be ventilated. The engine shall
be shut down and cooled prior to crank/soak cleaning.
All drains shall be open.
• Concentrated B & B 3100 solvent, acetone, and isopro-
pyl alcohol are flammable and toxic to skin, eyes, and
respiratory tract. Skin, eye, and respiratory protection is
required. Avoid repeated or prolonged contact. Use with
good ventilation.
CAUTION
Be certain that checklists have been established for packager-
furnished equipment. Consult the packager’s manual for
mandatory pre-start procedures, especially making sure that
the packager-furnished lube supply sub-system is activated
and operational prior to any motoring sequence. Failure to
comply may result in part damage.
(1) Disconnect pressure sensor lines from PS3 and P48 locations on gas turbine to
prevent water collection in lines and subsequently affecting engine operation.
(2) Cover electronic devices below gas turbine, such as fuel metering valve, to pre-
vent entry of water that may affect engine operation.
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(3) If crank/soak cleaning is not preceded by an extended shutdown period, perform a
normal shutdown (including 5 minutes at core idle for cooling). Refer to
Chapter 8, Volume I of this manual for engine shutdown procedures.
(4) Allow gas turbine to cool so that outside surfaces are less than 200°F (93°C).
WARNING
If natural gas is used to drive the starter, additional safety
precautions are required. These include safety measures for
combustible gases and venting of starter exhaust to a safe
location.
NOTE
While motoring the engine with the starter, ensure that a minimum
lube pressure of 6 psig (41 kPa) is maintained.
(5) To expedite cooling, motoring starter is permissible. Dry motoring procedures are
contained in to Chapter 8, Volume I of this manual. Limit starter duty cycles to
those defined in Chapter 5, Volume I.
B. Perform crank/soak cleaning cycle as follows:
(1) Motor HP rotor to 2,000 rpm and allow speed to stabilize. Low pressure (LP)
rotor speed should be 200-300 rpm. Allow LP rotor speed to stabilize before
initiating water flow.
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CAUTION
In below freezing conditions, antifreeze agents shall be added to
the water. The use of non-isopropyl alcohol, ethylene glycol,
and additives containing chlorine, sodium, or potassium are not
permitted since they may attack titanium and other metals in the
engine.
NOTE
• Total solids in the wash and rinse waters shall be no more than
100 ppm. The ph factor shall be between 6.5 and 8.5 at 77°F
(25°C). Potable water will normally meet these requirements.
Water-wash solution should be at room temperature and a flow
rate of approximately 20 gpm (76 liters/minute).
• Residual waste following water-wash with solvent should be
disposed of in accordance with local environmental regulations
for the specific geographic location. Users should contact the
solvent supplier for details relative to the solvent used.
• Packager-supplied control system will open the VIGVs and
will close the VBVs. The VSVs will remain on schedule.
• The number of wash cycles required to clean a gas turbine
depends on the starting condition and the effectiveness of
the wash solution/process.
• In some cases, off-line soak washing may not prove to be
effective in restoring performance of its unit. In these cases,
compressor top case hand cleaning of HPC blades and
vanes may be necessary. As compressor fouling also affects
stall margin, a heavily fouled compressor may lead to a stall
event.
(2) Inject 20 gallons (76 liters) of water-wash solution through crank/soak
water-wash manifold while motoring HP rotor at approximately 2,000 rpm and LP
rotor at 200-300 rpm.
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CAUTION
Packager-supplied control system shall automatically close
the water wash injection valve if LP rotor speed drops below
200 RPM or HP rotor speed drops below 2000 RPM. Water
injection at lower speeds may result in water entering LP or
HP compressors rotors, which may result in major engine
damage.
(3) After completion of wash solution injection, close the variable inlet guide vanes
(VIGVs) and maintain variable bypass valves (VBVs) in closed position. Allow
rotors to coast to a stop and the solution to soak for a minimum of 10 minutes.
Operator experience will determine soak time.
NOTE
• For systems with driven equipment having large rotational
inertia, it may not be practical to allow the rotors to coast
to a stop. The soak will be a rolling soak.
• During wash cycle, approximately 10 percent of the water
and cleaning solution will leak through the engine casings
and openings to the exterior of the engine.
• The number of rinses required depends on the condition of
the engine prior to wash, the quantity of wash solution used,
and the effectiveness of the rinse.
C. Complete rinse cycles as follows:
(1) Open inlet drain, bleed air collector drain, exhaust collector drains, and module
drains to remove any wash solution and rinse water after washing is complete.
(2) Use a minimum of 25 gallons (95 liters) of 160 to 180°F (71 to 82°C) water, while
motoring HP rotor at approximately 2,000 rpm and LP rotor at 200-300 rpm.
NOTE
Rinsing performed using unheated water will require more
water to achieve the same rinsing effectiveness as heated water.
(3) Repeat rinse until water sample at turbine exhaust is clear. If conductivity check-
ing is possible, conductivity should be similar to that of clear rinse water.
(4) After rinsing, shut off water supply.
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(5) Regulate pneumatic starter air supply for normal operation.
(6) Open low pressure compressor (LPC) variable bleed valves.
D. As an option, operator may inspect gas turbine to determine if cleaning process was
adequate as follows:
(1) After completion of the rinse cycles, allow rotors to coast to a complete stop.
(2) Borescope inspect LPC and high pressure compressor (HPC) rotors per
WP 4015 00, Volume II of this manual, paying particular attention to stator/blade
airfoils.
(3) If excessive contaminants are still present, rewash as required.
E. Make a normal engine start and allow engine to run at synchronous idle for 2-3
minutes to dry engine.
9. On-Line Cleaning.
CAUTION
Antifreeze mixtures for on-line water-wash and rinse should
be used when ambient temperatures are 50°F (10°C) or less.
Formation of ice may result in major engine damage.
NOTE
On-line cleaning does not typically eliminate the need for off-
line cleaning and it is not effective in cleaning a significantly
fouled compressor. However, on-line cleaning will typically
extend the required intervals for off-line cleaning to maintain
the gas turbine performance.
A. Conduct on-line wash with water only. Use of detergent is not recommended.
Use of water to NOx suppression standards per specification MID-TD-0000-3
(Appendix A-3) is required.
B. Limit total amount of water to 100 gal/day (378.5 liters/day) maximum.
C. Refer to packager's manual for specific amount of water and frequency of on-line
wash.
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6
WP 4015 00
WORK PACKAGE
TECHNICAL PROCEDURES
BORESCOPE INSPECTION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 96
Page Change Page Change Page Change
No. No. No. No. No. No.
1 - 96 ...... 6
Alphabetical Index
Subject Page
Borescope Inspection General Information ................................................................................ 4
Combustion Chamber and Fuel Nozzle Borescope Inspection................................................... 33
Drive Motor, 2C14764, and Adapter, 1C8208, Installation........................................................ 5
Drive Motor, 2C14764, and Adapter, 1C8208, Removal ........................................................... 7
Borescope Set.............................................................................................................................. 8
High Pressure Compressor (HPC) Borescope Inspection........................................................... 22
High Pressure Turbine (HPT) Nozzle Borescope Inspection...................................................... 48
High Pressure Turbine (HPT) Rotor Borescope Inspection ........................................................ 62
High Pressure Turbine (HPT) Diffuser Borescope Inspection. Only required for cast
Diffuser, PN 9290M28P15 .......................................................................................................... 81
Inlet Gearbox (IGB) Spline Borescope Inspection. Only Required Before Service Bulletin
LM6000-IND-0220....................................................................................................................... 20
Low Pressure Compressor (LPC) Borescope Inspection............................................................ 12
Low Pressure Turbine (LPT) Borescope Inspection ................................................................... 82
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1. Introduction.
A. This work package contains instructions for borescope inspection.
B. Gain access to gas turbine borescope ports inside high pressure compressor (HPC) air
manifold by removing tubes per SWP 1913 02.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Maintenance Considerations Chapter 11
Preventive Maintenance Chapter 12
Variable Stator Vane (VSV) Rigging WP 1411 00
Gas/Steam Fuel System (NGS) Components Replacement WP 1510 00
Dual Fuel/Water Fuel System (NDW) Components WP 1511 00
Replacement
Gas/Water Fuel System (NGW) Components Replacement WP 1512 00
Liquid Fuel/Water Fuel System (NLW) Components WP 1513 00
Replacement
Gas Fuel System (NG) Components Replacement WP 1514 00
Igniter Plug Replacement WP 1516 00
Low Pressure Turbine Inlet Pressure (P48) Probe Replacement WP 1712 00
Core Module External Tubing, Electrical Leads, and Clamping SWP 1913 02
Low Pressure Compressor (LPC) Stages 0-3 Stator Vanes WP 2213 00
Replacement
Gas Turbine Water-Wash WP 4014 00
Variable Stator Vane Off-Schedule Inspection WP 4028 00
Illustrated Parts Breakdown GEK 105060
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3. Support Equipment.
Nomenclature Part No.
Spline Adapter, Manual or Front Drive Pad 1C8208G02
Guide Tube, Borescope - HPT Diffuser 1C9459P01
Drive Motor, Electric (115 VAC 50/60 and 2C14764G05
400 Hz, 28 VDC)
Drive Motor, Electric (220 VAC 50 Hz and 2C14764G06
28 VDC)
Flex Borescope Guide Tube 2C6948P06
Borescope Equipment (6 mm [or less] diameter Everest XLG3 VideoProbe
probe) with Optical Measurement Capability
Borescope Equipment (6 mm [or less] diameter XL Go VideoProbe
probe) with Optical Measurement Capability
4. Consumable Material.
Nomenclature Specification
Marking Ink Dykem (Water Based
White or Yellow)
Marking Pen Sharpie T.E.C.
(Water Based
White or Yellow)
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
Tape Local Purchase
Thread Lubricant GE Spec A50TF201
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P134 1
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6. Borescope Inspection General Information.
WARNING
• Gas turbine shall not be operating and shall be verified as
inoperable. If possible, lock out system so it cannot be rotated.
• Gas turbine shall be allowed to cool to a surface temperature
below 120°F (48.9°C) before performing borescope inspection.
• Ensure that all personnel are clear of gas turbine inlet before
rotating rotors.
CAUTION
To prevent foreign objects from entering the gas turbine, keep bores-
cope ports covered when they are not being used. Open one port at a
time.
A. Verify gas turbine will be inoperable during inspection.
B. Shut off main fuel inlet valve per packager's manual.
C. Allow gas turbine to cool to surface temperature below 120°F (48.9°C) prior to
borescope inspection.
D. Deactivate fire extinguishing system per packager's manual.
E. Enter enclosure access per packager's manual. Enclosure door must remain open.
F. Use borescope equipment, Everest XLG3 or XL Go VideoProbe System or equivalent, for
inspection of gas turbine.
NOTE
Drive motor, 2C14764G05, operates on 115 VAC or 28 VDC. Drive
motor, 2C14764G06, operates on 220 VAC or 28 VDC.
G. Use spline adapter, 1C8208, and drive motor, 2C14764, to rotate high pressure rotors during
borescope inspection of rotors. Install adapter and motor per paragraph 7. A manual ratchet
may be used instead of the drive motor.
H. For rotation of low pressure rotors, refer to packager's manual.
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7. Drive Motor, 2C14764, and Adapter, 1C8208, Installation.
NOTE
• The gas turbine inspection drive motor permits one operator to
control the rotation of the gas turbine high pressure rotors for pur-
pose of inspection. No other personnel are required. The inspec-
tion drive motor will allow the gas turbine high pressure rotors to
be rotated in either direction at a very slow, variable speed. The
drive motor will not rotate the low pressure rotors.
• The drive motor may be installed at alternate locations as
required. Spline adapter, 1C8208, is required for all drive motors.
Spline adapter, 1C8208, can be used at various accessory loca-
tions.
• The gas turbine can be rotated by hand using a 1/2-inch-drive
wrench in the borescope drive pad.
A. Remove nuts and washers that secure drive pad cover onto transfer gearbox (figure 1).
Remove cover from gearbox and discard preformed packing. Retain hardware for reinstalla-
tion.
1
NOTE
This drive pad may be utilized as an accessory drive. If so, the acces-
sory must be removed for access to the pad. Refer to the packager's
manual for removal/installation instructions.
B. Install adapter plate onto gearbox drive pad (figure 1). Secure with nuts provided with
adapter plate. Tighten nuts to 57-67 lb in. (6.5-7.5 N·m) of torque.
C. Install drive shaft onto drive motor and tighten setscrew.
D. Insert drive shaft through hole in center of adapter plate and into spur gear. Ensure drive shaft
splines mesh with spur gear splines.
E. Secure drive motor to adapter plate with bolts and washers supplied with drive motor.
Tighten bolts to 428-502 lb in. (48.4-56.7 N·m) of torque.
F. Connect drive motor cord to control unit J3 motor connector.
G. Connect remote control cord to control unit J2 remote connector.
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Figure 1. Drive Motor and Adapter Installation
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WARNING
Improperly grounded electrical equipment can cause severe shock
or death. Equipment shall be properly grounded before use.
H. Connect three-prong power cord to control unit J1 power connector. Plug three-prong con-
nector into power source.
I. Operate drive motor during borescope as follows:
(1) Move control unit power switch to ON position.
(2) Select direction of rotor rotation for particular borescope inspection.
(3) Move switch on remote control to forward or reverse as required. Adjust motor speed on
control unit to achieve desired rotor rotation speed. Operator may perform borescope
inspection as planned, and may vary speed and direction of rotation as required.
CAUTION
Before reversing direction of rotation, bring rotor to a complete stop.
Failure to stop the rotor before reversing rotation may result in
severe damage to the drive motor mechanism.
(4) To reverse direction of rotation, move directional selector to neutral position which
allows gas turbine to free wheel. Wait until rotor completely stops; then move direc-
tional selector to opposite direction.
8. Drive Motor, 2C14764, and Adapter, 1C8208, Removal.
WARNING
Improperly grounded electrical equipment can cause severe shock
or death. Equipment shall be properly grounded before use.
A. Switch control unit off and disconnect power cord from power source and control unit.
B. Disconnect remote control and drive motor from control unit.
C. Remove drive motor from adapter plate by removing drive motor bolts and washers
(figure 1). Loosen setscrew on drive shaft and remove drive shaft from drive motor.
D. Remove nuts that secure adapter plate onto transfer gearbox. Remove adapter plate from
gearbox.
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NOTE
If drive pad is used for driving an accessory, install the accessory per
the packager's manual.
E. Install preformed packing, J221P134, and drive pad cover (figure 1) onto transfer gearbox and
secure with nuts and washers removed during drive motor installation. Tighten nuts to 57-67
lb in. (6.5-7.5 N·m) of torque.
9. Borescope Set.
NOTE
The following instructions apply to the Everest XLG3 and XL Go VideoProbe
systems borescope equipment. Refer to the manufacturer’s instructions if
using an alternate borescope set.
A. For description and operating instructions for the Everest XLG3 VideoProbe system (figure 2)
or XL Go VideoProbe system (figure 3), refer to the borescope unit instruction manual or con-
tact GE Inspection Technologies. Refer to the manufacturer’s instructions if using an alternate
borescope set.
B. Guide Tube.
(1) Guide tube, 2C6948, is to be used with the Everest XLG3 or XL Go VideoProbe
systems, or equivalent, when borescope inspecting the HPT shrouds.
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Figure 2. Borescope Equipment, Everest XLG3 VideoProbe System
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Figure 3. Borescope Equipment, XL Go VideoProbe System
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C. Borescope Set Assembly and Use.
WARNING
• Improperly grounded electrical equipment can cause severe
shock or death. Equipment shall be properly grounded before
use.
• To maintain explosion protection, do not operate borescope if
lamp module pressure is not within specified limits.
CAUTION
• Do not do a borescope inspection if the temperature inside the
engine is above 150°F (65.6°C).
• If the engine starter is used to motor the engine, the engine hot
section inspections shall be done in less than 20 minutes after the
motoring cycles are completed. Local temperature rise due to
engine temperature soak-back may damage the borescope.
NOTE
The following instructions apply to the Everest XLG3 and XL Go VideoProbe
systems borescope equipment. Refer to the manufacturer´s instructions if using
an alternate borescope set.
(1) For description and operating instructions for the Everest XLG3 VideoProbe system
(figure 2) or XL Go VideoProbe system (figure 3), refer to the borescope unit instruction
manual or contact GE Inspection Technologies. Refer to the manufacturer’s instructions
if using an alternate borescope set.
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10. Low Pressure Compressor (LPC) Borescope Inspection.
CAUTION
To prevent foreign objects from entering the gas turbine, keep bores-
cope ports covered when they are not being used. Open one port at a
time.
NOTE
Purchaser must provide equipment for rotation of the LPC rotor for
borescope inspection of the LPC. Refer to packager's manual for pro-
cedure.
A. Remove borescope plugs from borescope ports S4-1 through S4-4 in variable inlet guide
vane (VIGV) and LPC. See figure 4.
B. Rotate rotor and use borescope probe to view rotor blades. Identify first blade to left of two
locking lugs as blade number 1 for stage being viewed.
C. Borescope inspect LPC blades and vanes per table 1, figure 4A, and figure 5.
2
D. Record condition and report discrepancies for disposition and corrective action.
E. Install borescope plugs into borescope ports S4-1 through S4-4 as follows:
(1) Ensure borescope plug threads are clean.
(2) Coat borescope plug threads and mating surfaces with thread lubricant.
(3) Install borescope plugs into S4-1 through S4-4 borescope ports. See figure 4.
(4) Tighten VIGV borescope plugs S4-1 and S4-4 to 95-105 lb in. (10.8-11.8 N·m) of torque
and safety-wire.
(5) Tighten LPC case borescope plugs S4-2 and S4-3 to 95-105 lb in. (10.8-11.8 N·m) of
torque and safety-wire.
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Figure 4. LPC Borescope Ports
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Figure 4A. LPC Stage 4 Vane Bumper Inspection (Sheet 1 of 2)
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Figure 4A. LPC Stage 4 Vane Bumper Inspection (Sheet 2 of 2)
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Figure 5. LPC Rotor Blade Inspection
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Table 1. LPC Borescope Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Stage 0 Rotor Blades for:
a. SPRINT® 0.030 inch (0.76 mm) Not repairable Replace blades*
erosion on deep
leading edge
2. Stages 0 through 3 Rotor Blades for:
a. Cracks Not serviceable Not repairable Replace blades*
b. Nicks, dents, Not serviceable Not repairable Replace blades*
scratches, and
pits in root area
c. Nicks, dents, Any number, Not repairable Replace blades*
and scratches in 0.005 inch (0.13 mm)
leading or deep, 1/8 inch
trailing edges, (3.2 mm) in diameter
and contour for dents, and 1/2 inch
surfaces, except (12.7 mm) long for
root area scratches
d. Tip curl Both corners on each Not repairable Replace blades*
blade tip, not more than
1/4 inch (6.35 mm)
across blade tip, lead-
ing or trailing edge
e. Pits/erosion Any number, Not repairable Replace blades*
except root 0.005 inch (0. 13 mm)
area deep, no limit on
diameter spacing
f. Tip discolora- Any amount, if there Not repairable Replace blades*
tion resulting are no cracks
from rub
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Table 1. LPC Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
3. Stage 4 Rotor Blades for:
a. Cracks Not serviceable Not repairable Replace blades*
b. Nicks, dents, Any number of dents, Not repairable Replace blades*
and scratches 0.020 inch (0.51 mm)
on leading or deep, 1/8 inch
trailing edges (3.2 mm) in diameter.
Any number of
scratches, 0.005 inch
(0.13 mm) deep,
1/2 inch (12.7 mm)
long
c. Nicks, dents, Any number, Not repairable Replace blades*
and scratches 0.020 inch (0.51 mm)
on contour deep, 1/2 inch
surfaces (12.7 mm) diameter or
length
d. Tip curl Both corners on each Not repairable Replace blades*
blade tip, not more than
0.100 inch (2.54 mm)
across blade tip, lead-
ing or trailing edge, if
there are no indica-
tions of having struck
adjacent vanes during
operation
e. Tip burrs Not serviceable Not repairable Replace blades*
f. Tip cracks Not serviceable Not repairable Replace blades*
g. Tip tears Not serviceable Not repairable Replace blades*
h. Tip discolora- Any amount, if there Not repairable Replace blades*
tion resulting are no cracks
from rub
i. Tip material Not serviceable Not repairable Replace blades*
missing at
leading edge
and/or trailing
edge corners
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Table 1. LPC Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
4. Inner Shrouds for:
a. Cracks Two per 360 degree Not repairable Replace shroud*
ring or one per ring
half, 1/4 inch
(6.35 mm) long
b. Nicks and Any number, Not repairable Replace shroud*
scratches 0.03 inch (0.76 mm)
deep, with minimum
separation of 1/4 inch
(6.35 mm)
c. Dents Any number, Not repairable Replace shroud*
0.06 inch (1.52 mm)
deep, with smooth
contour
d. Missing Any amount -- --
anodize
e. Bushing protru- Any number, Not repairable Replace bushings per
sion into air- provided vane is not WP 2213 00
stream wearing into bushing
and protrusion is less
than 0.060 inch
(1.52 mm)
f. Fretting on OD Any number, Not repairable Replace shroud*
surface from 0.065 inch (1.65 mm)
vane contact deep
5. Stages 0 through 4 Stator Vanes for:
a. Cracks Not serviceable Not repairable Replace vane*
b. Nicks and Any number, Not repairable Replace vane*
scratches 0.03 inch (0.76 mm)
deep, with minimum
separation of 1/4 inch
(6.35 mm)
c. Dents Any number, 0.06 inch Not repairable Replace vane*
(1.52 mm) deep, with
smooth contour
Change 6 19
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Table 1. LPC Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
d. Leading or Any amount, Any amount, Blend vane per
trailing edge 0.03 inch (0.75 mm) 0.06 inch (1.50 mm) Chapter 11
damage deep deep
e. Nicks and Any number, Not repairable Replace vane*
scratches within 0.015 inch (0.38 mm)
1/2 inch deep, with minimum
(12.7 mm) of separation of 0.10 inch
leading or (2.54 mm)
trailing edge
6. Stages 4 Stator Vane Bumper for:
a. Rubber tongue Any number, any -- --
protrusions length
(figure 4A)
* NOTE: May be repairable; consult GE for disposition of replaced parts.
11. Inlet Gearbox (IGB) Spline Borescope Inspection.
Only Required Before Service Bulletin LM6000-IND-0220. See figure 5.A
3
CAUTION
• Do not rotate engine while the borescope equipment is inserted into
the engine. Damage to equipment and/or engine could occur.
• Ensure proper operator orientation of borescope probe with engine
prior to inspection. Flexible scope components could become lodged
if inserted into the inlet gearbox bevel gears.
• Assure proper equipment is utilized for inspection. A 6 mm flex bore-
scope with straight tip is recommended. Utilization of different
equipment could cause flexible scope components to become lodged.
A. Remove the four bolts per flange, one gasket, and B-sump vent manifold from the aft side of
the front frame (just aft of the air collector) at the 2:00 and 10:00 o'clock positions aft looking
forward (ALF). Place tape over open port (10:00 o'clock position) on left side once pipe has
been removed.
B. Remove any additional clamps or attaching bolts as required to remove manifold.
20 Change 6
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Figure 5.A. Inlet Gearbox Spline Borescope Inspection. Before Service Bulletin LM6000-IND-0220
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C. On right hand port, insert the flexible borescope approximately 15 inches (38.1 cm) into the
frame. The scope will traverse two turns and exit the front frame strut with the IGB housing
and pressurizing holes visible.
CAUTION
Flexible scope components could become lodged if inserted into the
inlet gearbox bevel gears.
D. Carefully enter the IGB assembly through the pressurizing holes. The inlet gearbox bevel
gears are immediately forward of this location, the flexible probe must be articulated aft,
towards the No. 3R bearing and the inlet gearbox splines.
E. Proceed aft approximately 2 inches (5.1 cm) towards the No. 3R bearing and the inlet gearbox
splines.
F. Inspect the area for evidence of iron oxide “sludge”. Iron oxide “sludge” buildup has been
determined to be evidence of spline wear as a result of non-optimized lubrication.
G. If iron oxide “sludge” is present, notify GE and provide photos/documentation of IGB spline
wear condition.
H. Remove the flexible borescope being careful not to move the borescope forward toward the
inlet gearbox bevel gears.
I. Lubricate bolts with thread lubricant. Install four bolts per flange point, with one gasket and
B-sump vent manifold from the aft side of the front frame (just aft of the air collector) at the
2:00 and 10:00 o'clock positions aft looking forward (ALF). Torque bolts to 62-68 lb in.
(7.0-7.7 N·m).
J. Reinstall any bolt, washers, nuts or clamps that were also removed to B-sump vent manifold.
Torque bolt or nut to 62-68 lb in. (7.0-7.7 N·m).
12. High Pressure Compressor (HPC) Borescope Inspection.
CAUTION
To prevent foreign objects from entering the gas turbine, keep borescope
ports covered when they are not being used. Open one port at a time.
A. Open variable stator vanes (VSV) per WP 1411 00.
B. Zero index HPC rotor as follows:
(1) Gain access to borescope port S5-11 through the stage 11 bleed air manifold per
SWP 1913 02 and remove S5-11 borescope plug.
4
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Figure 6. HPC Rotor Zero Index
(2) Rotate rotor clockwise (forward looking aft) and use borescope probe to view stage 12
rotor blade platforms. Locate first blade to left of two locking lugs. See figure 6.
NOTE
The locking lugs are two blades apart. The rotor blades rotate CCW as
viewed through the borescope.
(3) Position this blade in line with leading edge of stage 12 stator vane (as viewed through
the borescope). Identify this blade as blade No. 1. The next blade to appear will be blade
No. 2. See figure 6.
(4) The HPC rotor is now zero-referenced for all stages of compressor and HPT rotor blades.
Inspection of each applicable stage must start with HPC rotor positioned back to zero
reference point at stage 12.
C. Gain access to borescope ports S5-7, S5-8, and S5-9 through the stages 7 and 8 bleed air man-
ifolds per SWP 1913 02 and remove S5-7, S5-8, and S5-9 borescope plugs.
D. Remove borescope plugs from borescope ports S5-0 through S5-6, S5-10, S5-12, and S5-13
from HPC case. See figure 7.
E. Borescope inspect HPC blades and vanes per table 2 and figures 8, 9, and 10.
Change 6 23
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Figure 7. HPC Borescope Ports
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F. If damage is found, inspect adjacent stages to assess total damage. Record condition and
report discrepancies for disposition and corrective action.
G. Install borescope plugs S5-0 through S5-13 as follows:
(1) Ensure borescope plug threads are clean prior to installation.
(2) Coat S5-0 through S5-13 borescope plug threads and mating surfaces with
antiseize compound.
(3) Install borescope plugs into S5-0 through S5-13 borescope ports. See figure 7.
(4) Tighten borescope plugs S5-0 through S5-13 to 95-105 lb in. (10.8-11.8 N·m) of torque
and safety-wire or safety-cable.
Table 2. HPC Borescope Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
NOTE
On gas turbines operating with SPRINT® system, stage 1 blades
shall be replaced after 16,000 hours of SPRINT® operation or as
defined in Chapter 12, Table 12-1, of this manual.
1. Stages 1 through 14 Rotor Blades for:
NOTE
• Severe stalls may cause blade-to-case rubs which may induce
blade tip cracking that is hard to detect following the event.
• A “Boroblend” process is available with the capability of
blending some cases of HPC blades distress through the bores-
cope port without removal of the top stator case. This proce-
dure requires use of special equipment and qualified and
approved personnel. A single, one-time borescope inspection
of the repaired blades is required 500 hours after blending by
this process. Contact your Customer Support Manager to
request determination of the applicability of this process.
a. Rubs on stage 2 – – Inspect blades for
cracks, tip discolora-
tion, burrs, and high
metal
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Table 2. HPC Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Cracks Not serviceable on Not repairable Replace blades
stages 1 through 11.
Any number, any
amount on stages 12
through 14, if cracks
are in radial direction
along tip of blade
c. Nicks and dents Any number, 0.15 inch Not repairable Replace blades
on center panel (3.8 mm) in diameter,
if indications do not
extend across blade,
are not within 0.20 inch
(5.1 mm) of leading
and trailing edges, and
do not make hole
d. Tip corners that Any amount, maxi- Not repairable Replace blades
are missing mum of six blades per
stage, if there is no
unserviceable damage
downstream. If damage
is found, borescope
inspect all downstream
blades
NOTE
Tip clang damage is a sign of a compressor hard stall. See
WP 4028 00 for additional requirements.
e. Tip clang marks Any number, any Not repairable Replace blades
amount, if there are no
cracks
f. Tip curl Any amount, if damage Not repairable Replace blades
does not engage with
stator parts during
operation
g. Tip None allowed on – Blend to remove
discoloration stage 2 discoloration
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Table 2. HPC Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
h. Bent blades Any number, any Not repairable Replace blades
amount, if blades do
not engage with stator
parts during operation
i. Corrosion and Any amount – Water-wash per
dirt WP 4014 00
j. Abrasive Any amount – Water-wash per
deposits WP 4014 00
(usually found
on leading
edges)
k. Platform Any amount on stage 1 Not repairable Replace blades
shingling blades. Not service-
able on stages 2
through 14 blades
l. Platform Any amount – –
bowing
m. Burrs and high Any amount permit- – Stage 2 only: blend to
metal on blade ted, except stage 2 remove high metal or
tips from wear burrs. FPI for tip cracks
after blending
When rotor is exposed,
remove rub and burr
evidence on all stages
and inspect for tip
cracks on all rubbed
blades
n. Leading and Trailing Edges of Stages l through 9 Rotor Blades for:
(1) Tears, Any number of nicks Not repairable Replace blades
nicks, and and dents, 0.05 inch
dents (1.3 mm) deep, if blade
is not torn or bent.
Torn edges are not
serviceable
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Table 2. HPC Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
o. Stage 1 Blade Only:
(1) Tears, Area A: Not repairable Replace blades
nicks, and Serviceable, if not
dents on more than 0.02 inch
leading and (0.5 mm) deep, and
trailing blade is not torn or
edges bent. Torn edges not
(figure 11) serviceable
Area B: Not repairable Replace blades
Serviceable, if not
more than 0.05 inch
(1.3 mm) deep, and
blade is not torn or
bent. Torn edges not
serviceable
p. Stage 3 Blade Only:
(1) Tears, Area A: Not repairable Replace blades
nicks, and Serviceable, if not
dents more than 0.010 inch
on leading (0.25 mm) deep, and
and trail- blade is not torn or
ing edges bent. Torn edges not
serviceable
Area B: Not repairable Replace blades
Serviceable, if not
more than 0.05 inch
(1.3 mm) deep, and
blade is not torn or
bent. Torn edges not
serviceable
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Table 2. HPC Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
q. Leading and Trailing Edges of Stages 10 through 14 Rotor Blades for:
(1) Tears, Any number of nicks Not repairable Replace blades
nicks, and and dents, 0.05 inch
dents (1.3 mm) deep, if blade
within is not torn or bent. Any
0.30 inch number of nicks and
(7.6 mm) dents, 0.120 inch
of blade tip (3.05 mm), maximum
of six blades per stage
(2) Tears, Any number of nicks Not repairable Replace blades
nicks, and and dents, 0.05 inch
dents more (1.3 mm) deep, if blade
than is not torn or bent. Torn
0.30 inch edges are not
(7.6 mm) serviceable
away from
blade tip
r. Stage 1 Rotor Blades for:
(1) Cracks on Not serviceable Not repairable Replace blade(s)
midspan
shroud
(2) Missing Not serviceable Not repairable Replace blade(s)
material on
midspan
shroud
(3) Circumfe- Not serviceable Not repairable Replace blade(s)
rential gap
between
midspan
shrouds
(4) Shingling Not serviceable Not repairable Replace blade(s)
of mid-
span
shroud
(5) Distortion Any amount -- --
of plat-
forms
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Table 2. HPC Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
(6) Cracks on Any number, any -- --
platforms amount
s. Carboloy Wear Pad on Mid Span Shroud Interlock Surface of Stage 1 Rotor Blades for:
(1) Chipped 10 percent of pad may Not repairable Replace blades
pad be missing
(2) Cracked Not serviceable Not repairable Replace blades
pad
(3) Pad wear, Any amount, if remain- Not repairable Replace blades
smooth, or ing pad thickness is
stepped approximately
0.010 inch (0.25 mm)
(4) Missing Not serviceable Not repairable Replace blades
pad
2. Stages 1 and 2 Blade Retainers for:
a. Cracks Not serviceable Not repairable Replace retainer
b. Missing tabs Not serviceable Not repairable Replace retainer
3. Rotor Spools and Disks for:
NOTE
Excessive amounts of missing rub coat can result in loss of stall
and performance margin.
a. Missing rub Any amount -- --
coat
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5
Figure 8. HPC Rotor Blade Tip Clang Inspection
6
Figure 9. HPC Rotor Blade Inspection
8
7
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Figure 10. HPC Rotor Stage 1 Blade Midspan Shroud
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Figure 11. HPC Stages 1 and 3 Blade Inspection
13. Combustion Chamber and Fuel Nozzle Borescope Inspection.
CAUTION
To prevent foreign objects from entering the gas turbine, keep bores-
cope ports covered when they are not being used. Open one port at a
time.
A. Remove borescope plugs S6-1 and S6-3 through S6-6 from the compressor rear frame (CRF).
Remove the upper ignitor plug (borescope port S6-2) per WP 1516 00. See figure 12.
9
B. Borescope inspect the combustion and fuel nozzles per table 3 and figures 13, 14, 15, and
16. Record condition and report discrepancies for disposition and corrective action.
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Figure 12. Combustor and HPT Borescope Ports
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Table 3. Combustion Chamber Borescope Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
COMBUSTION CHAMBER
1. All Surfaces for:
a. Discoloration Any amount – –
b. Carbon Limit of 0.110 inch – Contact GE M&I
accumulation (2.79 mm) thick (360°)
on venturi throat
2. Dome Assembly (Dome Plate, Trumpet/Splash Plate, and Swirler Cup) (figure 13) for:
a. Distortion of Any amount – –
trumpets or
swirler cup
b. Axial or radial Any number that is not Not repairable Replace assembly
combustor connected
cooling hole
cracks in dome
plate
c. Circumferen- Any number, less than Not repairable Replace combustor
tial cracks in 0.50 inch (12.7 mm) assembly
dome plate long; or five less than
1.0 inch (25.4 mm) long
and 2.0 inches (50.8 mm)
separation between
cracks
d. Missing metal Ten per dome plate, Not repairable Replace combustor
from overhang max size 0.50 inch by assembly
area in dome 1.00 inch (12.7 by
plate (figure 14) 25.4 mm)
e. Burn through Three per dome plate, Not repairable Replace assembly
combustor max size 0.50 inch by
holes in dome 1.00 inch (12.7 by
plate 25.4 mm)
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Table 3. Combustion Chamber Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
f. Burning and (a) If first row of Not repairable Replace combustor
missing metal cooling holes is assembly
on edge of visible as new
splash plate (figure 16B, 1.): Any
amount up to and
including three rows
visible (not service-
able if fourth row vis-
ible)
(b) If first row of Not repairable Replace combustor
cooling holes is not assembly
visible as new
(figure 16B, 2.): Any
amount up to and
including two rows
visible (not service-
able if third row visi-
ble)
g. Missing TBC & Any amount – –
base coat on
face of splash
plate
h. Burning on face Any amount without hole – –
of splash plate through face
(other than on
edge)
i. Burn through 1 per plate quadrant, Inspect again within –
holes on face of 0.125 sq. in. 1000 hours
splash plate (80.65 sq. mm) max per Not repairable (Report Replace combustor
(other than on hole findings to GE) assembly
edge)
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Table 3. Combustion Chamber Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
3. Inner/Outer Combustion Liner Panels for (figure 15):
a. Circumferential cracks
(1) Circumfer- Any number, if Not repairable Replace combustor
ential cracked area between assembly
cracks on two dilution holes is next
panels with to at least three adjacent
dilution areas between dilution
holes holes that have no cracks
NOTE
A dilution land is the liner area between two dilution holes.
b. Axial cracks Any number, less than Not repairable Replace combustor
0.50 inch (12.7 mm) assembly
long. Ten cracks that go
all the way across liner
are serviceable on each
liner panel. Crack must
not be in more than two
panels
c. Connected Any number, if the cracks Not repairable Replace combustor
cracks are within limits for axial assembly
and circumferential
cracks. More than two
connected cracks are not
serviceable
d. Burn Six burned through areas Not repairable Replace combustor
through/miss- per panel. Panel can have assembly
ing metal six damaged areas that
(figure 15) are less than 0.40 by
0.40 inch (10.16 by
10.16 mm) and separated
by at least
6.0 inches (152.4 mm)
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Table 3. Combustion Chamber Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
e. Missing over- Fourteen cracked out Not repairable Replace combustor
hangs areas, 0.50 by 0.10 inch assembly
(figure 15) (12.7 by 2.54 mm) per
combustor assembly, pro-
vided no axial alignment
with three adjacent pan-
els
f. Distortion Any amount, within Not repairable Replace combustor
1/2 inch (12.7 mm) from assembly
original contour
4. Cowl for (figure 12):
a. Burns (fuel Three burned areas of Not repairable Replace combustor
nozzle 0.25 by 1.0 inch (6.35 by assembly
removed) 25.4 mm) on each fuel
nozzle
b. Cracks (fuel None allowed Not repairable Replace combustor
nozzle assembly
removed)
5. Fuel nozzle for:
a. Carbon on fuel Up to 0.13 inch (3.3 mm) Any amount Remove fuel nozzle
nozzle thick - not blocking fuel and clean/inspect to
passages determine cause of
carbon
b. Shroud wear on 0.015 inch (0.38 mm) Not repairable Replace fuel nozzle
coated diameter maximum. Not more than
(area A) 180° of
(figure 16C.) circumference
c. Wear on conical 0.015 in. (0.38 mm) max- Not repairable Replace fuel nozzle
surface (area B) imum. Not more than
(figure 16C.) 180º of circumference
d. Cracks None allowed Not repairable Replace fuel nozzle
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Table 3. Combustion Chamber Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
6. Primary swirlers for:
a. Bore wear Visually inspect per – –
paragraph 12.BA
Bore material thickness Serviceable –
above 50 percent of origi-
nal material thickness
Bore material thickness – Reduce inspection
below 50 percent of orig- interval to 2000 hours,
inal material thickness 6 months, or 225 cycles
whichever occurs first
Bore material thickness – Reduce inspection
below 25 percent of orig- interval to 1000 hours,
inal material thickness 3 months, or 100 cycles
whichever occurs first
Wear-through of swirler Not repairable Replace combustor
bore assembly
b. Anti-rotation Any amount on either Not repairable Replace combustor
tab wear tab, including disengaged
and crossed-over tabs,
and
(a)Not worn into retainer – –
is serviceable
(b)Wear into retainer – –
0.50 inch (12.7 mm)
or less is serviceable
and requires inspec-
tion every 500 hours
(c)Wear into retainer – –
greater than 0.50 inch
(12.7 mm) is not
serviceable.
c. Cracking of One or more through Not repairable Replace combustor
primary swirler cracks extending full assembly
bore length of swirler bore
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Table 3. Combustion Chamber Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
7. Venturi (secondary swirlers) for:
a. Holes None allowed Not repairable Replace combustor
b. Through cracks None allowed Not repairable Replace combustor
c. Micro cracks in Any amount – –
TBC on I.D.
surface
BA. Inspect primary swirlers, venturi (secondary swirlers), and nozzles per table 3, figure 16A,
and figure 16B, as follows:
(1) Matchmark fuel nozzles with their respective locations on CRF assembly.
(2) Remove fuel nozzles per WP 1510 00 (Gas/Steam), WP 1511 00 (Dual Fuel/Water),
WP 1512 00 (Gas/Water), WP 1513 00 (Liquid Fuel/Water), or WP 1514 00 (Gas Fuel).
Place nozzles in secure area.
(3) Visually evaluate condition of swirlers.
(4) Install fuel nozzles per appropriate WP.
C. Install borescope plugs and igniter plug as follows:
(1) Install the upper igniter plugs per WP 1516 00.
(2) Ensure borescope plug threads are clean.
(3) Coat borescope plug threads and mating surfaces with thread lubricant.
(4) Install borescope plugs into S6-1 and S6-3 through S6-6 ports. See figure 12.
(5) Tighten CRF borescope plugs S6-1 and S6-3 through S6-6 to 115-135 lb in.
(13.0-15.2 N·m) of torque and safety-wire.
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Figure 13. Combustion Section Liner Inspection
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Figure 14. Combustion Liner Dome and Igniter Tube Inspection
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Figure 15. Inner/Outer Liner Cracks
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Figure 16. Inner/Outer Liner Burns and Missing Metal
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Figure 16A. Swirler Inspection for Wear (Sheet 1 of 2)
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Figure 16A. Swirler Inspection for Wear (Sheet 2 of 2)
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Figure 16B. Splash Plate Inspection
Figure 16C. Fuel Nozzles Tip Inspection
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14. High Pressure Turbine (HPT) Nozzle Borescope Inspection.
CAUTION
To prevent foreign objects from entering the gas turbine, keep bores-
cope ports covered when they are not being used. Open one port at a
time.
A. Remove borescope plugs as follows (figure 12):
NOTE
There are six combustion chamber borescope ports. It is not necessary
to remove the UV sensors at borescope ports S6-2 and S6-5 during a
normal borescope inspection.
(1) Remove borescope plugs S6-1 and S6-4 from the CRF.
(2) Remove igniter plugs (borescope ports S6-3 and S6-6) per WP 1516 00.
(3) Remove borescope plugs S7-1 and S7-2 from the HPT stator case.
B. Borescope inspect HPT stage 1 nozzle per table 4 and figure 17.
C. Borescope inspect HPT stage 2 nozzle per table 5 and figure 18.
D. Borescope inspect cavity outboard of HPT stage 2 nozzle and 11th stage check valves per
table 5A and figures 18A and 18B.
E. Inspect borescope plugs S7-1 and S7-2 per table 5B and figure 18C.
F. Record condition and report discrepancies for disposition and corrective action.
G. Install borescope plugs and igniter plug as follows (figure 12):
(1) Install igniter plugs per WP 1516 00.
(2) Ensure borescope plug threads are clean.
(3) Coat borescope plug threads and mating surfaces with thread lubricant.
(4) Install borescope plugs into S6-1 and S6-4 ports.
(5) Tighten CRF borescope plugs S6-1 and S6-4 to 115-135 lb in. (13.0-15.2 N·m) of torque
and safety-wire or safety-cable.
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(6) Install borescope plugs into S7-1 and S7-2 ports.
(7) Tighten HPT borescope plugs S7-1 and S7-2 to 115-135 lb in. (13.0-15.2 N·m) of torque
and safety-wire.
Table 4. HPT Stage 1 Nozzle Borescope Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Leading Edge of Vanes for:
a. Cracks that Any number, 0.50 inch Not repairable Replace stage 1 nozzle
connect nose (12.7 mm) long, with assembly
holes minimum separation of
0.25 inch (6.4 mm), if
no material is missing
b. Cracks that go Any number, if no Not repairable Replace stage 1 nozzle
out from nose material is missing assembly
holes but do not
connect nose
holes
c. Burn through or Not serviceable Not repairable Replace stage 1 nozzle
erosion/miss- assembly
ing material
d. Burns or Combined total area, Not repairable Replace stage 1 nozzle
erosion 0.20 square inch assembly
(charred only, (1.3 square cm) per
no missing vane, maximum of four
material) vanes per 90 degree
arc. No missing metal
in inserts allowed. If
adjacent vanes have
damage, replace three
fuel nozzles that are
upstream from dam-
aged vanes
2. Concave Surface of Vanes for:
a. Radial cracks Any number, if no Not repairable Replace stage 1 nozzle
out of gill holes material is missing assembly
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Table 4. HPT Stage 1 Nozzle Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Other cracks Any number, if no Not repairable Replace stage 1 nozzle
(not in gill hole material is missing assembly
rows)
c. Burns and Any amount, if no Not repairable Replace stage 1 nozzle
erosion material is missing or assembly
burned through
d. Cracks in fillet Any number, if no Not repairable Replace stage 1 nozzle
area adjacent to material is missing assembly
inner and outer
platforms
3. Convex Surface of Vanes for:
a. Radial cracks Any number, if no Not repairable Replace stage 1 nozzle
material is missing assembly
b. Axial cracks Any number, if no Not repairable Replace stage 1 nozzle
material is missing assembly
c. Burns and Any amount, if no Not repairable Replace stage 1 nozzle
erosion material is missing or assembly
burned through
d. Cracks in fillet Any number, if no Not repairable Replace stage 1 nozzle
area adjacent to material is missing assembly
inner and outer
platforms
4. Trailing Edge of Vanes for:
a. Axial cracks Any number, if no Not repairable Replace stage 1 nozzle
(concave material is missing assembly
surface only) or
originating
from slots
adjacent to
trailing edge
b. Buckling or Any amount – –
bowing
50 Change 6
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Table 4. HPT Stage 1 Nozzle Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Burn through, Any amount, if com- Not repairable Replace stage 1 nozzle
tears, or bined total area of assembly
dents/missing missing material is less
material than 1.5 square inches
(9.7 square cm) per
vane and if combined
total area of material
missing from trailing
edge is less than
6.0 square inches
(38.7 square cm) per
assembly
5. All Areas of Vanes for:
a. Craze cracking Any amount – –
NOTE
Craze cracking is defined as numerous superficial surface cracks
which have no visual width or depth.
b. Nicks, scores, Any number, any – –
scratches, and amount
dents
c. Metal splatter Any amount – –
6. Inner and Outer Platforms for:
a. Cracks in Any number, any – –
parent metal amount
b. Nicks, scores, Any number, any – –
scratches, and amount
dents on
platform
surface
c. Burns or Any amount, if no Not repairable Replace stage 1 nozzle
erosion material is missing or assembly
burned through
d. Bulges or Not serviceable Not repairable Replace stage 1 nozzle
bowing assembly
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Figure 17. HPT Stage 1 Nozzle Inspection
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Figure 18. HPT Stage 2 Nozzle Inspection
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Table 5. HPT Stage 2 Nozzle Borescope Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Vanes for:
a. Axial cracks in Any number, 0.090 inch Not repairable Replace stage 2 nozzle
trailing edge that (2.28 mm) long; 2 per assembly
are more than vane, 0.50 inch
0.400 inch (12.7 mm) long; 1 per
(10.16 mm) from vane, 0.75 inch
the inner and the (19.1 mm) long, if cracks
outer platforms are 0.25 inch (6.4 mm)
apart and 0.400 inch
(10.16 mm) from inner
or outer platforms
b. Cracks in trailing Any number, if cracks do Not repairable Replace stage 2 nozzle
edge that are less not extend more than assembly
than 0.40 inch 1.0 inch (25 mm) in front
(10.16 mm) from of aft edge
inner and outer
platforms
c. Axial cracks in One per segment, Not repairable Replace stage 2 nozzle
leading edge that 0.30 inch (7.6 mm) long. assembly
break the surface Cracks that are parallel
layer to outer platform are not
permitted in Area C
(figure 18)
d. Cracks in Two, 1.5 inches (38 mm) Not repairable Replace stage 2 nozzle
concave surfaces long assembly
e. Cracks in convex Two, 1.00 inch Not repairable Replace stage 2 nozzle
surfaces (25.4 mm) long, if cracks assembly
are 0.50 inch (12.7 mm)
from outer or inner plat-
forms
NOTE
Craze cracking is defined as numerous superficial surface cracks
which have no visual width or depth.
f. Craze cracking Any amount – –
g. Nicks, scores, Any number, 0.03 inch Not repairable Replace stage 2 nozzle
scratches, or (0.8 mm) deep, 0.25 inch assembly
dents (6.4 mm) long
54 Change 6
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Table 5. HPT Stage 2 Nozzle Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
h. Buckling of Any amount within Not repairable Replace stage 2 nozzle
trailing edge 0.100 inch (25 mm) of assembly
original contour
i. Burns in convex One area, 1.0 square inch Not repairable Replace stage 2 nozzle
and concave (6.5 square cm), if no assembly
surfaces material is burned
through
j. Burns or spalling One area per vane, Not repairable Replace stage 2 nozzle
on leading edge 1.0 inch (25 mm) long assembly
(charred only, no radially, 0.25 inch
missing material) (6.4 mm) wide, if no
material is missing or
burned through
k. Material missing Largest single area per Not repairable Replace stage 2 nozzle
from trailing vane, 1.20 inches assembly
edge (30.5 mm) long,
1.00 inch (25.4 mm)
wide. Multiple areas per
vane allowed, total miss-
ing material not to
exceed 1.2 square inches
(7.7 square cm). Total
missing material not to
exceed 3.6 square inches
(23.2 square cm) per
90 degree arc. Missing
material in inserts not
allowed
2. Inner and Outer Platforms for:
a. Cracks between Any number, 0.150 inch Not repairable Replace stage 2 nozzle
vanes (3.81 mm) long. Two per assembly
platform segment,
0.600 inch (15.24 mm)
long, with minimum sep-
aration of 0.300 inch
(7.62 mm)
b. Nicks, scores, Any number, 0.03 inch Not repairable Replace stage 2 nozzle
scratches, and (0.8 mm) deep assembly
dents
Change 6 55
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Table 5. HPT Stage 2 Nozzle Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Cracks in outer Any number, 0.12 inch Not repairable Replace stage 2 nozzle
platform trailing (3.04 mm) long. Two per assembly
edge platform segment,
0.40 inch (10.2 mm)
long
d. Spalling of TBC Any amount – –
on outer platform
e. Material missing 1. Total material Not repairable Inspect stage 2 shrouds
due to complete missing per nozzle for side edge lip curl
burn through segment is greater (reference table 6). If
(area is totally than 0.02 sq in. lip curl is within on-
devoid of metal) (0.1 sq cm) and less site serviceable limits,
of the outer than 0.10 sq in. continue to operate.
platform trailing (0.6 sq cm) Repeat borescope
edge inspection every 1000
hours
2. Total material Not repairable Inspect stage 2 shrouds
missing per nozzle for side edge lip curl
segment is greater (reference table 6). If
than 0.10 sq in. lip curl is within on-
(0.6 sq cm) site serviceable limits,
continue to operate.
Repeat borescope
inspection every 500
hours
NOTE
Inspection of the stage 2 nozzles can be done in conjunction with the
semi-annual inspection of the T48 probes since the stage 2
nozzle trailing edge and stage 2 shrouds are best viewed through the
T48 and P48 bosses.
56 Change 6
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Table 5A. Cavity Outboard of Stage 2 Nozzles and 11th Stage Check Valve Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Cavity for pieces of Not serviceable Any amount Remove all material
broken flaps from
11th stage check
valves
(figure 18A.)
2. 11th stage check Not serviceable Any amount Replace valve flappers
valves for broken per WP 2415 00
or missing flaps
(figure 18B.)
Table 5B. HPT Borescope Plug Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. S7-1 and S7-2 Borescope Plugs for:
a. Plunger or Not serviceable Not repairable Replace plug
spring separa-
tion from
assembly
b. Loss of force Not serviceable Not repairable Replace plug
(spring should
force plunger to
full extension,
on flat surface,
plunger up)
c. Plunger tip Less than 0.170 in. Not repairable Replace plug
wear (4.32 mm) per
figure 18C
d. Non-uniform Not serviceable Not repairable Replace plug
wear or defor-
mation of
plunger tip
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Figure 18A. Cavity Outboard of Stage 2 HPT Nozzles Inspection
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Figure 18B. 11th Stage Check Valve Inspection (Sheet 1 of 2)
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Figure 18B. 11th Stage Check Valve Inspection (Sheet 2 of 2)
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Figure 18C. HPT Borescope Plug Inspection
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15. High Pressure Turbine (HPT) Rotor Borescope Inspection.
CAUTION
To prevent foreign objects from entering the gas turbine, keep borescope
ports covered when they are not being used. Open one port at a time.
A. Remove borescope plugs as follows (figure 12):
NOTE
There are six combustion chamber borescope ports. It is not necessary
to remove the UV sensors at borescope ports S6-2 and S6-5 during a
normal borescope inspection.
(1) Remove borescope plugs S6-1 and S6-4 from CRF.
(2) Remove igniter plugs (borescope ports S6-3 and S6-6) per WP 1516 00.
(3) Remove borescope plugs S7-1 and S7-2 from HPT stator case.
B. Establish HPT rotor blade reference per paragraph 11.
C. Borescope inspect HPT shrouds per table 6 and figure 19. Use Everest XLG3 or XL Go bore-
scope equipment or equivalent, and guide tube, 2C6948P06, at borescope ports S7-1 and S7-2.
D. Borescope inspect HPT stage 1 rotor blades per table 7 and figures 20 and 21.
E. Borescope inspect HPT stage 2 rotor blades per table 7 and figure 22.
F. Record condition and report discrepancies for disposition and corrective action.
G. Install borescope plugs and igniter plug as follows (figure 12):
(1) Install igniter plugs per WP 1516 00.
(2) Ensure borescope plug threads are clean.
(3) Coat borescope plug threads and mating surfaces with thread lubricant.
(4) Install borescope plugs into S6-l and S6-4 ports.
(5) Tighten CRF borescope plugs S6-1 and S6-4 to 115-135 lb in. (13.0-15.2 N·m) of torque
and safety-wire or safety-cable.
(6) Install borescope plugs into S7-1 and S7-2 ports.
(7) Tighten HPT borescope plugs S7-1 and S7-2 to 115-135 lb in. (13.0-15.2 N·m) of torque
and safety-wire.
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Table 6. HPT Stages 1 and 2 Shrouds Borescope Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Stage 1 Shrouds for:
a. Axial cracks Any number, Not repairable Replace stage 2 nozzle
0.150 inch (3.81 mm) assembly
long. Four cracks per
segment, 1.00 inch
(25.4 mm) long. One
crack per segment all
the way across seg-
ment, with 0.125 inch
(3.18 mm) separation
between cracks
b. Circumferen- Any number, any Not repairable Replace stage 2 nozzle
tial cracks amount, with minimum assembly
separation of
0.125 inch (3.18 mm)
c. Radial cracks in Three per segment, any Not repairable Replace stage 2 nozzle
forward wall amount, with minimum assembly
separation of 0.50 inch
(12.7 mm)
d. Connected Two per segment, if Not repairable Replace stage 2 nozzle
cracks cracks are within lim- assembly
its for axial and cir-
cumferential cracks
e. Material Maximum area of Not repairable Replace stage 2 nozzle
missing in 0.100 inch (2.54 mm) assembly
circumferential can be missing
direction
2. Stage 2 Shrouds for:
a. Wear and Any amount, if damage Not repairable Replace stage 2 nozzle
erosion does not go all the way assembly
through surface
Change 6 63
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Table 6. HPT Stages 1 and 2 Shrouds Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Axial cracks Any number, Not repairable Replace stage 2 nozzle
0.200 inch (5.08 mm) assembly
long. Four cracks per
segment, 1.00 inch
(25.4 mm) long. One
crack per segment all
the way across seg-
ment, with 0.125 inch
(3.18 mm) separation
between cracks
c. Circumferen- Four per segment, Not repairable Replace stage 2 nozzle
tial cracks 0.375 inch (9.53 mm) assembly
long, with minimum
separation of
0.125 inch (3.18 mm)
d. Connected Two per segment, if Not repairable Replace stage 2 nozzle
cracks cracks are within lim- assembly
its for the axial and cir-
cumferential cracks
e. Material Combined total area, Not repairable Replace stage 2 nozzle
missing from 0.100 inch (2.54 mm) assembly
circumferential in circumferential
or leading direction and
edges 0.750 inch (19.05 mm)
in axial direction, if
damage is less than
depth of seal slot
f. Disengaged or Any amount. Disen- Not repairable Inspect LPT per
missing HPT gaged leaf seals may paragraph 17
stage 2 extend into hot gas
leaf seal flowpath. If seen or
missing, borescope
inspect LPT
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Table 6. HPT Stages 1 and 2 Shrouds Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
g. Material Combined area is less Not repairable Replace stage 2 nozzle
missing from than 0.10 x 0.25 inch assembly
leading edge or (2.5 x 6.4 mm), if depth
side edges of missing material
through leading edge or
past side edge seal slots
h. Side edge lip 0.010 inch (0.25 mm) Not repairable Replace stage 2 nozzle
curl (noticeable step between adjacent assembly
step between side edges
shrouds)
10
Change 6 65
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Figure 19. HPT Stages 1 and 2 Shroud Inspection
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Table 7. HPT Rotor Blades Borescope Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Stage 1 Rotor Blades:
NOTE
During inspection of blades, visual evidence of plugged cooling
holes is not positive. Evidence of plugged cooling holes is accept-
able if crack, erosion, and burn limits are serviceable.
a. All Areas for:
(1) Missing Any amount, if there Not repairable Replace blade
coating are no holes or cracks
in oxidized area
(2) Oxidation Any amount, if there Not repairable Replace blade
of parent are no holes or cracks
metal in oxidized area
(green or
black dis-
coloration)
(3) Plugged Any number, if cracks, Not repairable Replace blade
cooling erosion, and burns are
holes within limits
b. Leading Edges for:
(1) Axial and Any number, if cracks Not repairable Replace blade
radial do not extend back to
cracks in gill holes
area A
because of
impact
damage
(figure 20)
(2) Axial and Not serviceable Not repairable Replace blade
radial
cracks in
area A
related to
missing
parent
metal due
to oxidation
(figure 20)
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Table 7. HPT Rotor Blades Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
(3) Radial Any number, if cracks Not repairable Replace blade
cracks out do not connect two
of leading holes and do not turn in
edge holes axial direction
in area B
(figure 20)
(4) Axial Not serviceable Not repairable Replace blade
cracks in
area B
(figure 20)
(5) Nicks and Any number, if damage Not repairable Replace blade
dents in and cracks do not
area A extend past gill holes
(figure 20)
(6) Nicks and Any number, if damage Not repairable Replace blade
dents in does not extend past
area B gill holes and there are
(figure 20) no tears, cracks, or
missing material
(7) Missing Any amount, if there Not repairable Replace blade
coating or are no holes or cracks
base metal in oxidized area or
due to oxi- underlying area
dation in
area C
(figure 21)
(8) Missing One area per blade, Not repairable Replace blade
material smaller in diameter
(base than span between
metal) three leading edge
holes or 0.24 inch
(6.1 mm), if it is not
below fifth concave gill
hole from top, there are
no cracks, and internal
leading edge cross over
wall is intact, maxi-
mum of two blades per
stage
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Table 7. HPT Rotor Blades Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
c. Tip Caps for:
(1) Missing Not serviceable. No Not repairable Replace blade
material material missing or
burned through to first
radial passage
d. Trailing Edges for:
(1) Cracks Not serviceable Not repairable Replace blade
(2) Nicks in Any number, if there Not repairable Replace blade
area A are no tears or cracks
(figure 20)
(3) Dents in Any number, smaller in Not repairable Replace blade
area A diameter than span
(figure 20) between four trailing
edge holes or
0.120 inch (3.05 mm),
and depth is less than
distance between two
trailing edge holes or
0.040 inch (1.02 mm).
Dents shall not extend
into trailing edge hole
(4) Tears in Not serviceable Not repairable Replace blade
area A
(figure 20)
(5) Coating or Any amount, if there Not repairable Replace blade
parent are no holes or cracks
metal miss- in oxidized area
ing due to
oxidation
e. Concave and Convex Surfaces for:
(1) Radial Any number, if cracks Not repairable Replace blade
cracks at do not connect two
gill holes holes and do not turn in
and film axial direction. Cracks
holes from bottom holes
must be shorter than
distance between holes
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Table 7. HPT Rotor Blades Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
(2) Radial Any number, if cracks Not repairable Replace blade
cracks out do not extend into next
of tip film film hole (in the direc-
holes tion of platform) and
do not turn in axial
direction
(3) Radial One crack permitted. Not repairable Replace blade
cracks Length must be less
other than than distance between
at gill or eight gill holes or
film holes 0.900 inch (22.86 mm).
Crack can extend to tip
of blade
(4) Nicks and Any number, if there Not repairable Replace blade
dents in are no tears, cracks, or
area A holes through material
(figure 20)
(5) Nicks and Any number, smaller in Not repairable Replace blade
dents in diameter than span
area B between two gill holes
(figure 20) on concave surface,
four trailing edge holes
on convex surface, or
0.120 inch (3.05 mm).
No tears, cracks, or
holes through material.
No damage allowed on
root radius
(6) Axial Not serviceable Not repairable Replace blade
cracks
(7) Missing Any amount, if there Not repairable Replace blade
coating in are no holes or cracks
areas D in oxidized area or
and E underlying area
(figure 21)
(8) Distortion, Not serviceable Not repairable Replace blade
burns, and
signs of
melting
70 Change 6
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Table 7. HPT Rotor Blades Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
f. Tip Area (Above Tip Film Holes) for:
NOTE
It is possible that the tip film holes extend into blade tip area
(figure 20).
(1) Radial Any number on con- Not repairable Replace blade
cracks cave surface, if cracks
do not extend more
than one hole below tip
film holes. Any num-
ber on convex surface,
if cracks do not extend
below second trailing
edge hole from top and
are not notched open
below first trailing
edge hole from top.
Three per blade that
extend to fourth trail-
ing edge hole from top,
if cracks are not
notched open below
first trailing edge hole
from top
(2) Axial Any number, if cracks Not repairable Replace blade
cracks do not extend below tip
of film holes
(3) Bent or Any amount, if damage Not repairable Replace blade
curled does not extend below
blade tips tip area
(4) Tears Any number, if tears do Not repairable Replace blade
not extend below tip
area
(5) Missing Any amount, if damage Not repairable Replace blade
material, does not extend below
except at tip area and internal air
trailing passages are not visible
edge where material is
missing
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Table 7. HPT Rotor Blades Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
(6) Missing Any amount, if damage Not repairable Replace blade
material at does not extend below
trailing first trailing edge hole
edge from top and internal
air passages are not
visible where material
is missing
g. Blade platform for:
(1) Oxida- Any amount, if there Not repairable Replace blades and
tion/corro- are no holes or cracks inspect LPT for
sion of in oxidized or corrosion
parent corroded area
metal or
black dis-
coloration
2. Stage 2 Rotor Blades:
NOTE
There are tip notches on the concave side of four blades 90 degrees
apart on the stage 2 rotor. The tip notches are for reference only
and are not signs of erosion.
a. Concave and Convex Surfaces for:
(1) Cracks Not serviceable Not repairable Replace blade
(2) Tears and Not serviceable Not repairable Replace blade
missing
material
(3) Dents and Not serviceable Not repairable Replace blade
nicks
within
0.500 inch
(12.70 mm)
of platform
72 Change 6
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Table 7. HPT Rotor Blades Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
(4) Dents and Any number, Not repairable Replace blade
nicks not 0.500 inch (12.70 mm)
within in diameter, if there are
0.500 inch no tears
(12.70 mm)
of platform
(5) Missing Any amount, if there Not repairable Replace blade
coating are no holes or cracks
in oxidized area
b. Leading Edges for:
(1) Nicks and Any number, any – –
dents amount
(2) Cracks in Any number, any Not repairable Replace blade
area A amount, if cracks are in
(figure 22) dent
(3) Cracks in Not serviceable Not repairable Replace blade
area B
(figure 22)
(4) Tears and Not serviceable Not repairable Replace blade
missing
material
(5) Missing Any amount, if there – –
coating are no holes or cracks
in oxidized area
c. Trailing Edges for:
(1) Cracks Not serviceable Not repairable Replace blade
(2) Nicks and Not serviceable Not repairable Replace blade
dents
within
0.500 inch
(12.70 mm)
of platform
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Table 7. HPT Rotor Blades Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
(3) Nicks and Any number, any – –
dents not amount
within
0.500 inch
(12.70 mm)
of platform
(4) Tears and Not serviceable Not repairable Replace blade
missing
material
d. Tips for:
(1) Bent or Any amount – –
curled
blade tips
(2) Tears and Any amount, if wall on Not repairable Replace blade
missing opposite side of blade
material is not damaged. One
area per blade,
0.300 inch (7.62 mm)
long, if damage is on
both sides of blade
(3) Radial Two per blade, one on Not repairable Replace blade
cracks each side of blade,
0.250 inch (6.35 mm)
long, if internal air pas-
sage cavity below tip
cavity shelf is not visi-
ble through cracks
(4) Axial Any number, Not repairable Replace blade
cracks 0.500 inch (12.70 mm)
long
e. Platforms for:
(1) Bowing Any amount, if plat- Not repairable Replace blade
form misalignment is
less than platform
thickness and there are
no cracks
12
11
13
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Figure 20. HPT Stage 1 Rotor Blade Inspection (Sheet 1 of 3)
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Figure 20. HPT Stage 1 Rotor Blade Inspection (Sheet 2 of 3)
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Figure 20. HPT Stage 1 Rotor Blade Inspection (Sheet 3 of 3)
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Figure 21. HPT Stage 1 Rotor Blade TBC Inspection Areas
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Figure 22. HPT Stage 2 Rotor Blade Inspection (Sheet 1 of 2)
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Figure 22. HPT Stage 2 Rotor Blade Inspection (Sheet 2 of 2)
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16. High Pressure Turbine (HPT) Diffuser Borescope Inspection.
Only required for cast Diffuser, PN 9290M28P15.
CAUTION
To prevent foreign objects from entering the gas turbine, keep bores-
cope ports covered when they are not being used. Open one port at a
time.
A. Remove fuel nozzle at 12:00 o'clock position per WP 1510 00 (Gas/Steam),
WP 1511 00 (Dual Fuel/Water), WP 1512 00 (Gas/Water), WP 1513 00
(Liquid Fuel/Water), or WP 1514 00 (Gas/Fuel). Place nozzles in secure area.
NOTE
Borescope guide tube, PN 1C9459P01, may be used to facilitate inser-
tion of flexscope.
B. Insert Everest XLG3 or XL Go, or equivalent, flexscope into fuel nozzle port, around/under
combustor cowl and inner liner and through holes in stage 1 HPT nozzle support and seal sup-
port (mini nozzle) until outer vanes of HPT diffuser are visible. Continue to insert flexscope
until entire trailing edge of adjacent vane is visible. See figures 22.A. and 22.B.
C. Borescope inspect entire length of transition radius between convex vane wall and aft wall of
vane ring to extent allowed by physical limitations of borescope equipment. See figure 22.B.
D. Retract borescope from HPT diffuser enough to allow rotation of core without
damaging borescope equipment.
CAUTION
Do not rotate engine while the borescope equipment is inserted into
rotating parts of the engine (HPT diffuser). Damage to equipment
and engine could occur.
E. Rotate core until next diffuser vane is visible.
F. Repeat inspection for all nine diffuser vanes.
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G. Document any indications by saving image with camera on borescope equipment. Document
the following:
(1) Any diffuser vane ring with a non-cracklike linear indication must be reviewed by GE
LM6000 Customer Support Engineering to determine serviceability.
(2) Any diffuser vane ring with an indication that is determined to be cracklike is unservice-
able and diffuser replacement is required.
H. Remove all borescope inspection tooling.
I. Re-install fuel nozzles per appropriate work package.
14
23
17. Low Pressure Turbine (LPT) Borescope Inspection.
CAUTION
To prevent foreign objects from entering the gas turbine, keep bores-
cope ports covered when they are not being used. Open one port at a
time.
NOTE
Purchaser must provide equipment for rotation of the LPT rotor for
borescope inspection of the LPT. Refer to the packager’s manual for
procedure.
A. Remove borescope plugs S8-2 through S8-4 from the LPT case and turbine rear frame (TRF).
See figure 23.
B. Remove P48 probe (borescope port S8-1) per WP 1712 00.
23
C. Borescope inspect the LPT vanes and blades per table 8 and figures 24, 25, 26, 27,
and 28.
D. Record condition and report discrepancies for disposition and corrective action.
E. Install borescope plugs S8-2 through S8-4 as follows (figure 23):
(1) Ensure borescope plug threads are clean.
(2) Coat borescope plug threads and mating surfaces with thread lubricant.
(3) Install borescope plugs into S8-2 through S8-4 ports.
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Figure 22A. HPT Rotor Diffuser Vane Wall Borescope Inspection
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Figure 22B. Diffuser Vane Ring Inspection Area
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Figure 23. LPT Borescope Ports
(4) Tighten LPT case borescope plugs S8-3 and S8-4 to 115-135 lb in.
(13.0-15.2 N·m) of torque and safety-wire.
(5) Tighten TRF borescope plug S8-2 to 115-135 lb in. (13.0-15.2 N·m)
of torque and safety-wire.
F. Install P48 probe per WP 1712 00.
24
25
26
27
28
29
30
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Figure 24. HPT Leaf Seals Wrapped Around EGT Probe and Airfoils
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Figure 25. LPT Stages 2 through 4 Stator Vane Inspection
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Figure 26. LPT Rotor Blade Inspection
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Figure 27. LPT Stage 1 Rotor Blade Inspection
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Figure 28. LPT Rotor Blade Shroud Circumferential Inspection
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Table 8. LPT Rotor and Stator Borescope Inspection
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
1. Stage 1 Nozzle Vanes:
a. All Areas for:
(1) Cracks One per vane Not repairable Replace LPT module
0.250 inch (6.35 mm)
long, if there are no
cracks in either adja-
cent vane (one on each
side)
(2) Nicks and Any number, any Not repairable Replace LPT module
dents amount, if there are no
tears
(3) Burns Any number of areas, Not repairable Replace LPT module
1.0 square inch
(6.5 square cm), if
burned vanes are sepa-
rated by at least two
vanes that are not
burned
(4) Tears One per vane, Not repairable Replace LPT module
0.50 inch (12.7 mm)
long, if combined total
area is less than
0.5 square inch
(3.2 square cm) per
stage
(5) HPT leaf Not serviceable Any amount Remove probe to disen-
seals in gage leaf seal and
contact inspect probe. Disen-
with EGT gaged seal can stay in
probe engine
(figure 24)
(6) HPT leaf Any number – –
seals
wrapped
around air-
foils
(figure 24)
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Table 8. LPT Rotor and Stator Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
b. Leading Edge Outer Platform for:
(1) Single No greater than Not repairable Reduce BSI interval to
crack (per 3.0 inches (76 mm) and every 1000 hours.
nozzle seg- not into airfoil fillet Contact GE Service
ment) Manager for disposition
No cracks allowed in Not repairable Replace LPT module
airfoil fillet
(2) Multiple Any amount, 0.5 inch Not repairable Replace LPT module
cracks (per (13 mm) long in axial
nozzle seg- direction with
ment) 0.05 inch (1.3 mm)
minimum spacing.
Total accumulative
length must not exceed
3.0 inches (76 mm)
c. Trailing Edge Outer Platform for:
(1) Cracks Any amount, 0.5 inch Not repairable Replace LPT module
(13 mm) long in axial
direction with
0.05 inch (1.3 mm)
minimum spacing per
segment. Total accu-
mulative length must
not exceed 1.5 inches
(38 mm). One crack
1.5 inches (38 mm),
long max permitted per
segment
CAUTION
The vane leading edge is the primary source of purge air to the aft
side of the stage 2 HPT disk rim. Any interference of this airflow
could damage the stage 2 HPT.
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Table 8. LPT Rotor and Stator Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
2. Stages 2 through 4 Stator Vanes (figure 25):
a. All Areas for:
(1) Cracks One per vane, Not repairable Replace LPT module
0.25 inch (6.35 mm)
long, if there are no
cracks in either adja-
cent vane (one on each
side)
(2) Nicks and Any number, any Not repairable Replace LPT module
dents amount, if there are no
tears
(3) Burns Any number of areas, Not repairable Replace LPT module
1.0 square inch
(6.5 square cm), if
burned vanes are sepa-
rated by at least one
vane that is not burned
b. Vane Fillet Radius for:
(1) Cracks One per vane, Not repairable Replace LPT module
0.50 inch (12.7 mm)
long, maximum of two
vanes per nozzle seg-
ment
3. Rotor Blades (figures 26, 27, and 28):
a. All Areas for:
(1) Cracks Not serviceable Not repairable Replace LPT module
b. Leading and Trailing Edges for:
(1) Nicks Any number, Not repairable Replace LPT module
0.040 inch (1.02 mm)
deep
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Table 8. LPT Rotor and Stator Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
(2) Dents Any number, if there Not repairable Replace LPT module
are no distortions (that
go out) on opposite
side of blade. Five,
with distortions less
than 0.050 inch
(1.27 mm) on opposite
side of blade. No cuts
or tears permitted in
bottom of dent
c. Concave and Convex Surfaces for:
(1) Dents Any number, if there Not repairable Replace LPT module
are no distortions (that
go out) on opposite
side of blade. Five on
each side of blade, with
distortions less than
0.02 inch (0.5 mm) on
opposite side of blade
(2) Nicks Any number, 0.03 inch Not repairable Replace LPT module
(0.8 mm) deep
d. Top Surface Rotor Blade Platforms (not including blade root radius) for:
(1) Nicks and Any number, 0.02 inch Not repairable Replace LPT module
dents (0.5 mm) deep
e. Outer Forward Seal Tooth on Stage 1 Rotor Blades (figure 27) for:
(1) Wear or Any amount, if not Not repairable Replace LPT module
erosion worn to platform
f. Seal Lips for:
(1) Material Any amount less than Not repairable Replace LPT module
that is 50 percent of initial
rubbed, material
turned, or
missing
g. Circumferential Mate Faces on Blade Shrouds (figure 28) for:
(1) Wear Any amount, if there is Not repairable Replace LPT module
(irregular or no related interlock
jagged) wear
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Table 8. LPT Rotor and Stator Borescope Inspection (Continued)
On-Site Max On-Site Max On-Site
Inspect Serviceable Limits Repairable Limits Corrective Action
h. Blade Shroud Interlocks (figure 28) for:
(1) Wear Not serviceable Not repairable Replace LPT module
(irregular or
jagged)
(2) Shingling Not serviceable Not repairable Replace LPT module
or unlatch-
ing
i. Blade Platforms for (Stage 1 Only) (figure 29):
(1) Misaligned Any amount not to – Replace blades
exceed 0.05 inch
(1.3 mm)
j. HPT leaf seals Not serviceable Any number Remove or dislodge
wrapped leaf seal through bore-
around airfoil scope port. Dislodged
(figure 24) leaf seal may stay in
engine. Inspect blades
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Figure 29. LPT Rotor Blade Shroud Circumferential Inspection
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0WP 4016 00
WORK PACKAGE
TECHNICAL PROCEDURES
LUBE OIL SAMPLING
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 2
6 Blank ...... 2
Alphabetical Index
Subject Page
Lube Oil Test............................................................................................................................... 3
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1. Introduction.
This work package contains instructions for lube oil sampling and test analysis.
2. Reference Material.
Title Number
Oil Analysis, Particle Count ARP598
Oil Analysis, Acid ASTM D664-58
Oil Analysis, Viscosity ASTM D445-65
Oil Analysis, Color ASTM D1500
Oil Analysis, Water ASTM D1744
Operation & Maintenance Manual GEK 105059
Lube and Scavenge Pump Chip Detector Inspection WP 4017 00
Lube and Scavenge Pump Screen Check WP 4020 00
Oil Analysis, SOAP NAVA1R 31-1-37
3. Support Equipment.
None required.
4. Consumable Material.
None required.
5. Expendable Material.
None required.
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6. Lube Oil Test.
A. Obtain lube oil sample as follows:
WARNING
• Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and
respiratory tract. Do not inhale, ingest, or let this mate-
rial touch you. Skin and eye protection is required.
Avoid repeated or prolonged contact. Use in a well-ven-
tilated area.
• Use thermal gloves when you move or touch hot or cold
parts. Hot or cold parts can cause injury.
CAUTION
Do not take oil sample from low drain point. Low drain point
may contain heavy sediments and provide incorrect indications.
(1) Shut down engine.
NOTE
All oil samples shall be taken from the same location.
(2) Obtain oil sample as follows:
(a) Obtain oil sample within 30 minutes after engine shutdown.
(b) Take oil sample from oil tank filler. Ensure oil extraction equipment and
container are clean and free of contaminates.
(c) If oil sample is obtained from a low drain point, such as the scavenge oil
discharge line, flow approximately l pint (0.5 liter) into a waste container and
then, without interrupting the flow, obtain oil sample.
B. Label the sample with the following information:
Sample Location ___________________________
Gas Turbine S/N ___________________________
Oil Type __________________________________
Date _____________________________________
Total Operating Hours _______________________
Change 2 3
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WP 4016 00
C. Deliver oil sample to laboratory for analysis. The oil sample shall be tested per table 1.
D. If limits of table 1 are exceeded, perform the following corrective action:
(1) Inspect lube and scavenge pump chip detectors and screens per WP 4017 00 and
WP 4020 00.
(2) Flush oil from lube and hydraulic systems as follows:
(a) Shut down engine and completely drain oil tank and as many service lines as
possible.
(b) Service oil tank with new lubricating oil. Always use oil from same
manufacturer.
(c) Operate engine for 5 minutes.
(d) Shut down engine and drain oil tank and service lines.
(e) Service oil tank with new lubricating oil.
E. If spectrographic oil analysis program (SOAP) analysis indicates an increasing trend in
wear, monitor oil contamination through increased sampling intervals. If maximum
limits are reached, change out engine and flush oil system per step D(2).
4 Change 2
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WP 4016 00
Table 1. Lube Oil Sample Testing
Step Test for Procedure Limit
1. Total Acid Number (TAN) Test per ASTM D664-58 1.0
2. Viscosity (Kinematic) Test per ASTM D445-65 Maximum change at 100°F (38°C)
from new oil reading +25% to -
10%
3. Color Test per ASTM D1500 4
4. Particle Count Test per SAE ARP598 For Lube NAS 7 Class
For HYD NAS 6 Class
5. SOAP Analysis: Atomic Absorption Method
Element Normal On Watch Shutdown Procedure
Iron (Fe) 0-3 4-7 8+ NAVAIR
31-1-37
Silver (Ag) 0-1 2-4 5+
Aluminum (Al) 0-1 2-4 5+
Chromium (Cr) 0-4 5-7 8+
Copper (Cu) 0-5 6-10 11+
Magnesium (Mg) 0-1 2-4 5+
Nickel (Ni) 0-3 4-6 7+
Silicon (Si) 0-20 21-36 37+
Titanium (Ti) 0-3 4-6 7+
Molybdenum (Mo) 0-3 4-6 7+
Lead (Pb) 0-3 4-6 7+
Tin (Sn) 0-15 16-22 23+
Zinc (Zn) 0-10 11-17 18+
SOAP Analysis: Atomic Emission Method
Element Normal On Watch Shutdown Procedure
Iron (Fe) 0-8 9-13 14+ NAVAIR
31-1-37
Silver (Ag) 0-3 4-6 7+
Aluminum (Al) 0-3 4-6 7+
Chromium (Cr) 0-6 7-9 10+
Copper (Cu) 0-12 13-19 20+
Magnesium (Mg) 0-6 7-9 10+
Nickel (Ni) 0-5 6-8 9+
Silicon (Si) 0-25 26-64 65+
Titanium (Ti) 0-5 6-8 9+
Molybdenum (Mo) 0-5 6-8 9+
Lead (Pb) 0-2 3-4 5+
Tin (Sn) 0-20 21-39 40+
Zinc (Zn) 0-15 16-22 23+
6. Water Test per ASTM D1744 1,000 PPM
Change 2 5/(6 Blank)
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WP 4017 00
7WP 4017 00
WORK PACKAGE
TECHNICAL PROCEDURES
LUBE AND SCAVENGE PUMP CHIP DETECTOR
CHECK
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS - ALL
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 0
Alphabetical Index
Subject Page
Chip Detector Inspection ............................................................................................................ 3
Chip Detector Installation ........................................................................................................... 7
Chip Detector Removal............................................................................................................... 3
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WP 4017 00
1. Introduction.
This work package contains instructions for inspection of the lube and scavenge pump chip
detectors.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Troubleshooting Chapter 10
Magnetic Chip Detector Replacement WP 1910 00
Lube and Scavenge Pump Screen Check WP 4020 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Dry Cleaning Solvent Fed Spec P-D-680,
Type II
Lubricating Oil MIL-L-23699
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P905 AR
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WP 4017 00
6. Chip Detector Removal.
A. Before removing the chip detectors, do the following:
(1) Verify gas turbine will be inoperable during inspection.
(2) Shut off main fuel inlet valve per packager's manual.
(3) Deactivate fire extinguishing system per packager's manual.
(4) Enter enclosure access per packager's manual. Enclosure door must remain open.
(5) Shut off oil supply to gas turbine.
B. Remove chip detectors from locations shown in figure 1. Remove chip detector from
housing bayonet mount by pushing knurled ring inward and rotating counterclockwise
(figure 2).
NOTE
Standard chip detector configuration is common scavenge, B-scavenge,
and transfer gearbox (TGB) scavenge. Optional chip detectors may be
installed in C-scavenge, D-scavenge, and E-scavenge ports.
2
1
7. Chip Detector Inspection.
A. Visually inspect chip detectors for foreign material (figure 3). If any foreign material
is found, analyze, and perform corrective action as follows:
3
(1) Isolate source of foreign material by identifying area from which material was
scavenged. Check lube and scavenge pump screens per WP 4020 00.
(2) Visually examine suspect material for identification of source. If material can be
visually identified as bearing material, such as roller, ball, and/or race fragments,
component replacement is the required corrective action. Bearing races, rollers,
and balls are magnetic, therefore, separating out any magnetic materials will help
identification. See table 1.
(3) Main gas turbine bearing distress normally increases lube scavenge temperatures
and gas turbine vibration. Review gas turbine log sheets for significant changes in
gas turbine logged parameters.
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WP 4017 00
Figure 1. Chip Detector Locations
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Figure 2. Chip Detector Components
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WP 4017 00
Figure 3. Chip Detector Inspection
Table 1. Component Failure Corrective Action
Chip Detector Possible Cause Corrective Action
1. TGB a. TGB failure a. Replace TGB
b. Inlet gearbox failure b. Replace gas turbine
c. 1B or 2R bearing failure c. Replace gas turbine
d. 3R bearing failure d. Replace gas turbine
2. B-Sump 4R/4B bearing failure Replace gas turbine
3. C-Sump 5R bearing failure Replace gas turbine
4. D- and E-Sump 6R/7R bearing failure Replace LPT module
5. Common Scavenge — Inspect chip detectors/
screens for source
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(4) If suspect material is found on TGB chip detector or in TGB screen, source must
be further identified. Remove lower drain plug and inspect TGB/A-sump area for
any distress.
(5) If suspect material is identified as bolt or rivet fragments, replace component as
indicated by screen identity. Bearing cage rivets indicate a radial drive shaft
failure.
(6) If suspect material is identified as pieces of preformed packing, gasket, safety
wire, coke, machining chip, or seal rub strip material, place gas turbine on watch,
e.g., check and clean chip detectors and scavenge pump screens daily and monitor
lube system parameters until problem is located or chip detectors and screens are
clean for two consecutive days, then resume normal inspection intervals.
(7) If more information is required, contact customer support manager for
clarification.
B. If chip detector is suspect of malfunctioning, check continuity as follows:
(1) Remove electrical connector per WP 1910 00.
(2) Check for open continuity of pins to housing and all pins to each other.
(3) Check continuity across chip detector tip control surfaces. Continuity shall not
exceed 10 ohms.
(4) If chip detector fails any of these checks, replace chip detector. Refer to
Chapter 10, Volume I of this manual for electrical lead and chip detector wiring
schematics and troubleshooting tables.
(5) Install electrical connector per WP 1910 00.
8. Chip Detector Installation.
WARNING
• Drycleaning solvent, P-D-680, Type II, is flammable and
toxic to skin, eyes, and respiratory tract. Skin, eye, and
respiratory protection is required. Avoid repeated or pro-
longed contact. (W-MIL-C13).
• When using compressed air for cleaning, cooling, or drying,
do not exceed 30 psig. Wear eye protection and do not direct
compressed air at self or others.
A. Clean chip detectors with dry cleaning solvent. Dry with shop air at 40 psig (276 kPa).
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WP 4017 00
B. Inspect preformed packings (figure 2) for damage. If required, replace preformed
packings.
WARNING
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.
C. Lubricate preformed packings with lubricating oil.
D. Install chip detectors in chip detector housing by pushing knurled ring inward and
rotating clockwise. Check for proper seating by twisting knurled ring back and forth
without pressing inward.
E. Leak-check chip detectors as follows:
WARNING
A safety observer shall be stationed adjacent to the enclosure
access.
(1) Open fuel supply valve and make a gas turbine start.
(2) Ensure gas turbine will not be operated above idle. Put on protective ear and hand
equipment. Deactivate fire extinguishing system per packager's manual.
(3) Station a safety observer adjacent to the enclosure access.
(4) Enter enclosure. Check for leaks. Make corrections as required.
(5) Exit enclosure, close enclosure access, and activate fire extinguishing system per
packager's manual.
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WP 4018 00
5WP 4018 00
WORK PACKAGE
TECHNICAL PROCEDURES
MAIN FUEL FILTER REPLACEMENT
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-5 ...... 0
6 Blank ...... 0
Alphabetical Index
Subject Page
Main Fuel Filter Installation ....................................................................................................... 5
Main Fuel Filter Removal ........................................................................................................... 3
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WP 4018 00
1. Introduction.
This work package contains instructions for replacing the main fuel filter.
2. Reference Material.
None required.
3. Support Equipment.
Nomenclature Part No.
Wrench, Strap A91C
4. Consumable Material.
Nomenclature Specification
Corrosion Preventive Oil MIL-L-6085
Isopropyl Alcohol Fed Spec TT-I-735
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed 110100-139 2
Packing, Preformed 140100-110 1
Packing, Preformed 140900-243 1
Filter Element AA9227F-1680 1
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WP 4018 00
6. Main Fuel Filter Removal.
WARNING
Gas turbine shall not be operating and shall be verified as
inoperable. If possible, lock out system so it cannot be
rotated.
A. Before removing main fuel filter, perform the following:
(1) Verify gas turbine will be inoperable during inspection.
(2) Shut off main fuel inlet valve per packager's manual.
(3) Deactivate fire extinguishing system per packager's manual.
(4) Enter enclosure access per packager's manual. Enclosure door must remain open.
B. Remove main fuel filter as follows (figure 1):
1
WARNING
Fuel in liquid, vapor, or mist form is flammable, irritating to the
skin and respiratory tract, and poisonous in the digestive tract.
Remove saturated clothing, wash skin well, don't swallow liquid,
and don't breathe mist or vapor.
(1) Remove filter bowl drain plug. Place suitable container under filter bowl and
drain fluid. Remove and discard preformed packing.
(2) Remove filter bowl using a strap wrench, turning counterclockwise.
(3) Remove and discard filter element, AA9227F-1680.
(4) Remove and discard preformed packings from filter head and bowl.
WARNING
• Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
• When using compressed air for cleaning, cooling, or drying,
do not exceed 30 psig. Wear eye protection and do not direct
compressed air at self or others.
C. Clean filter bowl with isopropyl alcohol. Dry with air.
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WP 4018 00
Figure 1. Main Fuel Filter Element
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7. Main Fuel Filter Installation.
A. Install main fuel filter element as follows (figure 1):
WARNING
Corrosion Preventive Oil, MIL-L-6085, is flammable and
toxic to skin, eyes, and respiratory tract. Skin, eye, and res-
piratory protection is required.
(1) Lubricate preformed packing with corrosion preventive oil, MIL-L-6085.
(2) Install two new preformed packings, PN 110100-139, onto each end of new filter
element, PN AA9227F-1680.
(3) Install new preformed packing, PN 140900-243, onto filter bowl.
(4) Push filter element, PN AA9227F-1680, into filter bowl.
(5) Install filter bowl onto filter head and hand-tighten, using strap wrench to
maximum of 50 lb ft (67.8 N·m).
(6) Install new preformed packing, PN 140100-110, onto drain plug and install plug
into filter bowl. Tighten plug to 40-65 lb in. (4.5-7.3 N·m) of torque.
(7) Safety-cable or safety-wire drain plug onto filter bowl and filter bowl onto filter
head.
B. Leak-check main fuel filter as follows:
WARNING
A safety observer shall be stationed adjacent to the enclosure access.
(1) Open fuel supply valve and make a gas turbine start.
(2) Ensure gas turbine will not be operated above idle. Put on protective ear and hand
equipment. Deactivate fire extinguishing system.
(3) Station a safety observer adjacent to the enclosure access.
(4) Enter enclosure. Check for leaks. Make corrections, as required.
(5) Exit enclosure, close enclosure access, and activate fire extinguishing system per
packager's manual.
5/(6 Blank)
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WP 4019 00
0WP 4019 00
WORK PACKAGE
TECHNICAL PROCEDURES
FUEL PUMP FILTER CHECK
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-7 ...... 0
8 Blank ...... 0
Alphabetical Index
Subject Page
Fuel Pump Filter - Inspection...................................................................................................... 3
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WP 4019 00
1. Introduction.
This work package contains instructions for inspecting and cleaning the fuel pump filter.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Liquid Fuel Pump Assembly, Fuel Filter Assembly, Fuel WP 1810 00
Pump Adapter, and Quick Disconnect Adapter -
Replacement
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
Nomenclature Part No.
Ultrasonic Cleaner Local Purchase
4. Consumable Material.
Nomenclature Specification
Corrosion Preventive Oil MIL-C-6529
Corrosion Preventive Oil MIL-C-16173
Corrosion Preventive Oil MIL-L-6085
Dry Cleaning Solvent Fed Spec P-D-680,
Type II
Isopropyl Alcohol Fed Spec TT-I-735
Lubricating Oil MIL-L-23699
Sodium Dichromate Crystals Local Purchase
(Commercial Grade, 99.5% min)
Sulfuric Acid Local Purchase
(Technical Grade, 66° Baume)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Element, Strainer Filter 102705 1
Packing, Preformed 78151-133 1
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6. Fuel Pump Filter - Inspection.
WARNING
Gas turbine shall not be operating and shall be verified as
inoperable during inspection period. If possible, lock out
system so it cannot be rotated.
A. Before removing fuel pump filter, perform the following:
(1) Verify gas turbine will be inoperable during check.
(2) Shut off main fuel inlet valve per packager's manual.
(3) Deactivate fire extinguishing system per packager's manual.
(4) Enter enclosure access per packager's manual. Enclosure door must remain open.
B. Remove fuel pump filter as follows (figure 1):
1
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin eyes, and res-
piratory tract. Skin and eye protection is required. Avoid
repeated or prolonged contact. Use in a well-ventilated
area.
(1) Remove two screws and washers that secure cap and valve assembly to fuel
pump. Drain fuel into suitable container.
(2) Using two screws removed in step (1) as jackscrews, remove cap and valve
assembly with strainer element.
(3) Remove strainer element from cap and valve assembly.
(4) Remove preformed packing and discard.
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WP 4019 00
Figure 1. Fuel Pump Filter
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C. Clean strainer element as follows:
WARNING
Drycleaning solvent, P-D-680, type II, is flammable and
toxic to skin, eyes, and respiratory tract. Skin, eye, and res-
piratory protection is required. Avoid repeated or pro-
longed contact.
(1) Immerse strainer element in dry cleaning solvent.
(2) Clean element with soft bristle brush. Dislodged contaminant should float from
sieves.
(3) Hold element up to light and visually inspect for contamination between inside
and outside diameter sieves.
(4) If all contaminates cannot be removed by brushing method, proceed as follows:
WARNING
Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or pro-
longed contact. Use in a well-ventilated area.
(a) Pour isopropyl alcohol into cleaning tank of an ultrasonic cleaner to depth of
approximately 3 inches (76 mm).
(b) Connect cleaner to suitable power source, making sure cleaner switches are
in OFF or normal position.
(c) Allow approximately 10-15 seconds for unit to warm up.
(d) Position strainer element in cleaner tank and turn cleaner on for
approximately 15 minutes.
(e) Adjust cleaner for maximum surface agitation.
(f) Allow cleaner to run desired cycle; then shut off cleaner and remove strainer
element.
(g) Cover cleaner tank to prevent contamination of cleaning fluid.
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(5) As an alternate method to ultrasonic cleaning, proceed as follows:
WARNING
• Always add acid to solution to prevent violent reactions
and splash burns. Wear protective gloves, apron, and
face shield.
• Sulfuric acid is highly toxic to skin, eyes, and respiratory
tract. Skin and eye protection and vapor control are
required. Avoid all contact.
NOTE
It may be necessary to heat solution to approximately 150°F
(66°C) in order to dissolve sodium dichromate crystals.
(a) Immerse strainer element in saturated solution of 1 liter of sulfuric acid and
20 grams of sodium dichromate crystals.
(b) Leave element in solution for 1 minute.
WARNING
When using compressed air for cleaning, cooling, or drying,
do not exceed 30 psig. Wear eye protection and do not direct
compressed air at self or others.
(c) Thoroughly rinse element in clean water and dry with clean, moisture free
compressed air.
(d) If strainer element is not completely clean, repeat steps (a), (b), and (c).
(6) Dispose of all waste fluids per federal and state EPA standards.
D. Install fuel pump filter as follows (figure 1):
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and res-
piratory tract. Skin and eye protection is required. Avoid
repeated or prolonged contact. Use in a well-ventilated area.
(1) Lubricate preformed packing, P/N 78151-133, with lubricating oil.
(2) Install preformed packing onto cap and valve assembly.
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WP 4019 00
(3) Assemble strainer element onto cap and valve assembly making sure element is
firmly bottomed against shoulder on cap and valve assembly.
(4) Install cap and valve assembly, with strainer element, into fuel pump and secure
with two screws and washers.
(5) Tighten screws to 45-55 lb in. (5.1-6.2 N·m) of torque above running torque.
E. Leak-check fuel pump filter as follows:
WARNING
A safety observer shall be stationed adjacent to the enclo-
sure access.
(1) Open fuel supply valve and make a gas turbine start.
(2) Ensure gas turbine will not be operated above idle. Put on protective ear and hand
equipment. Deactivate fire extinguishing system per packager's manual.
(3) Station safety observer adjacent to enclosure access.
WARNING
Inlet and exhaust area of running engine are extremely dan-
gerous. Stay clear and wear ear protection
(4) Enter enclosure. Check for leaks. Make corrections as required.
(5) Exit enclosure, close enclosure access, and activate fire extinguishing system per
packager's manual.
7/(8 Blank)
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LM6000 PC GEK 105059
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WP 4020 00
7WP 4020 00
WORK PACKAGE
TECHNICAL PROCEDURES
LUBE AND SCAVENGE PUMP SCREEN CHECK
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-8 ...... 0
Alphabetical Index
Subject Page
Lube and Scavenge Pump Inlet Screens Inspection.................................................................... 4
Lube and Scavenge Pump Inlet Screens Installation .................................................................. 7
Lube and Scavenge Pump Inlet Screens Removal...................................................................... 4
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GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4020 00
1. Introduction.
This work package contains instructions for inspection of the lube and scavenge pump inlet
screens.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Lube and Scavenge Pump Chip Detector Inspection WP 4017 00
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Isopropyl Alcohol Fed Spec TT-I-735
Lubricating Oil MIL-L-23699
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
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WP 4020 00
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Plug:
Nomenclature Part No. Qty
Packing, Preformed M83248/1-905 4
Packing, Preformed M83248/1-910 3
Packing, Preformed M83248/1-912 3
Packing, Preformed NAS1595-5 7
Chip Detector:
Nomenclature Part No. Qty
Packing, Preformed J221P905 3
Screens:
Nomenclature Part No. Qty
Packing, Preformed M83248/1-905 1
Packing, Preformed NAS1593-121 1
Packing, Preformed NAS1595-10 2
Packing, Preformed NAS1595-12 3
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
GEK 105059 LM6000 PC
Volume II GE Industrial AeroDerivative Gas Turbines
WP 4020 00
6. Lube and Scavenge Pump Inlet Screens Removal.
WARNING
Gas turbine shall not be operating and shall be verified as inoper-
able during inspection period. If possible, lock out system so it
cannot be rotated.
A. Before removing lube and scavenge pump inlet screens, perform following:
(1) Verify gas turbine will be inoperable during inspection.
(2) Shut off main fuel inlet valve per packager's manual.
(3) Deactivate fire extinguishing system per packager's manual.
(4) Enter enclosure access per packager's manual. Enclosure door shall remain open.
(5) Shut off lube oil supply to gas turbine per packager's manual.
B. Remove lube and scavenge pump inlet screens (figure 1) as follows:
1
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
(1) Remove drain plugs or chip detectors from transfer gearbox (TGB), accessory
gearbox (AGB), B-sump, C-sump, D-sump, and E-sump inlet screens. Remove
and discard preformed packings. Examine chip detectors per WP 4017 00. Drain
residual oil into approved waste container.
(2) Remove lube inlet screen and six lube scavenge inlet screens from lube and
scavenge pump, and identify by location using tags or vibropeen etch. Remove
and discard preformed packings.
7. Lube and Scavenge Pump Inlet Screens Inspection.
A. Visually inspect inlet screens for foreign material. If any foreign material is found,
analyze as follows and perform corrective action:
(1) Isolate source of foreign material by identifying area from which material was
scavenged.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4020 00
Figure 1. Lube and Scavenge Pump Screens Check
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4020 00
Table 1. Component Failure Corrective Action
Filter Screen Possible Cause Possible Corrective Action
A. TGB 1. TGB failure 1. Replace TGB
2. Inlet gearbox failure 2. Replace gas turbine
3. 1B or 2R bearing failure 3. Replace gas turbine
4. 3R bearing failure 4. Replace gas turbine
B. B-Sump 4R/4B bearing failure Replace gas turbine
C. C-Sump 5R bearing failure Replace gas turbine
D. D- and E-Sump 6R/7R bearing failure Replace LPT module
E. AGB Scavenge AGB failure Replace AGB (Note 1)
NOTE:
Some packager and GE supplied components use gas turbine lube oil and are scavenged through
the AGB. Material in the AGB could be indicative of failure of the gearbox mounted components
and not failure of the AGB itself.
(2) Visually examine suspect material for identification of source. If material can be visu-
ally identified as bearing materials, such as roller, ball and/or race fragments, required
corrective action is component replacement. Bearing races, rollers, and balls are mag-
netic, therefore, separating out any magnetic materials will help identification. Material
property analysis may be required. Main engine bearings cannot be replaced on-site.
Main engine bearings may be replaced at depot level. Main bearing failures require
replacement of gas turbine or module. See table 1 for possible corrective action details.
(3) Main gas turbine bearing distress usually increases lube scavenge temperatures and gas
turbine vibration, therefore, gas turbine log sheets should be reviewed for significant
changes in gas turbine logged parameters.
(4) If suspect material is found in TGB screen, source shall require further
identification. Inspect TGB/A-sump area for any distress.
(5) If suspect material is identified as bolt or rivet fragments, replace component as indi-
cated by screen identity.
(6) If suspect material is identified as pieces of preformed packing, gasket, safety wire,
coke, machining chip, or seal rub strip material, place gas turbine on watch, e.g., check
and clean scavenge pump screens daily and monitor lube system parameters until prob-
lem is located or screens are clean for two successive days, then resume normal inspec-
tion intervals.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4020 00
8. Lube and Scavenge Pump Inlet Screens Installation.
See figure 1.
WARNING
• Alcohol is flammable and toxic to skin, eyes, and respiratory
tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
• When using compressed air for cleaning, cooling, or drying,
do not exceed 30 psig. Wear eye protection and do not direct
compressed air at self or others.
A. Clean screens with isopropyl alcohol and soft bristle brush. Dry with shop air at 30
psig (207 kPa) maximum pressure. Replace any damaged screens.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
B. Lubricate new packings, P/N M83248/1-912, with lubricating oil, and install onto
TGB, B-, and C-sump inlet screens. Install inlet screens into same ports from which
they were removed and tighten to 55-70 lb in. (6.3-7.9 N·m) of torque.
C. Lubricate new packings, P/N M83248/1-908, with lubricating oil, and install onto
AGB, D-, and E-sump inlet screens. Install inlet screens into same ports from which
they were removed and tighten to 55-70 lb in. (6.3-7.9 N·m) of torque.
D. Lubricate packing, P/N NAS1593-121, with lubricating oil, and install on lube inlet
screen. Install lube inlet screen into same port from which it was removed and tighten
to 55-70 lb in. (6.3-7.9 N·m) of torque.
E. Lubricate new packings, P/N M83248/1-905 or P/N J221P905, if chip detectors are
used, with lubricating oil. Install packings onto drain plugs or chip detectors and
install in AGB, TGB, B-, C-, D-, and E-sump inlet screens. Tighten drain plugs or chip
detectors to 55-70 lb in. (6.3-7.9 N·m) of torque. Safety-wire plugs or chip detectors.
F. Turn on lube oil supply to gas turbine.
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WP 4020 00
G. Leak-check main lube and scavenge pump inlet screens as follows:
WARNING
A safety observer shall be stationed adjacent to the enclosure
access.
(1) Open fuel supply valve and make a gas turbine start per packager's manual.
(2) Ensure gas turbine will not be operated above idle.
(3) Put on protective ear and hand equipment.
(4) Deactivate fire extinguishing system per packager's manual.
(5) Station safety observer adjacent to enclosure access.
WARNING
Inlet and exhaust areas of running engines are extremely danger-
ous. Stay clear and wear ear protection.
(6) Enter enclosure. Check for leaks in lube system, and correct leaks as required.
(7) Exit enclosure, close enclosure access, and activate fire extinguishing system per
packager's manual.
(8) Shut down engine.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4021 00
0WP 4021 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE GEOMETRY PUMP/HYDRAULIC
CONTROL UNIT FILTER CHECK
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-6 ...... 5
Alphabetical Index
Subject Page
VG Pump/HCU Filter Inspection................................................................................................ 3
Change 5 1
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UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4021 00
1. Introduction.
This work package contains instructions for inspection of the variable geometry (VG)
pump/hydraulic control unit (HCU) filter.
2. Reference Material.
Title Number
Illustrated Parts Breakdown GEK 105060
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Corrosion Preventive Oil MIL-L-6085
Dry Cleaning Solvent Fed Spec P-D-680,
Type II
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Element, Filter AC-B244F-2440 1
Packing, Preformed M83248/1-110 1
Packing, Preformed M83248/1-243 1
2 Change 5
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4021 00
6. VG Pump/HCU Filter Inspection.
WARNING
Gas turbine shall not be operating and shall be verified as inop-
erable during inspection period. If possible, lock out system so it
cannot be rotated.
A. Before removing VG pump/HCU filter, perform the following:
(1) Verify gas turbine will be inoperable during inspection.
(2) Shut off main fuel inlet valve per packager's manual.
(3) Deactivate fire extinguishing system per packager's manual.
(4) Enter enclosure access per packager's manual. Enclosure door shall remain open.
(5) Shut off oil supply to gas turbine per packager's manual.
B. Remove VG pump/HCU filter as follows (figure 1):
1
WARNING
Lubricating oil, MIL-L-23699, is toxic to skin, eyes, and respira-
tory tract. Skin and eye protection is required. Avoid repeated or
prolonged contact. Use in a well-ventilated area.
(1) Remove filter bowl drain plug. Drain fluid into a suitable container. Remove and
discard preformed packing.
(2) Using strap wrench, remove filter bowl.
(3) Remove and discard filter element.
(4) Visually inspect filter bowl for large particles.
(5) Remove and discard preformed packing from filter bowl.
Change 5 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4021 00
Figure 1. VG Pump/HCU Filter Inspection
4 Change 5
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4021 00
C. Install VG pump/HCU filter as follows (figure 1):
WARNING
• Drycleaning solvent, P-D-680, Type II, is flammable and toxic
to skin, eyes, and respiratory tract. Skin, eye, and respiratory
protection is required. Avoid repeated or prolonged contact.
• When using compressed air for cleaning, cooling, or drying,
do not exceed 30 psig. Wear eye protection and do not direct
compressed air at self or others.
(1) Clean filter bowl with dry cleaning solvent. Blow dry with compressed air.
WARNING
Lubricating oil, MIL-L-6085, is flammable and toxic to skin,
eyes, and respiratory tract. Skin, eye, and respiratory protection
is required.
(2) Lubricate preformed packings with corrosion preventive oil.
(3) Install preformed packing, P/N M83248/1-243, into filter head.
(4) Push filter element, P/N AC-B244F-2440, into filter bowl.
(5) Install filter bowl onto filter head and hand-tighten until filter bowl bottoms.
Tighten filter bowl to maximum of 50 lb ft. (67.8 N·m) of torque.
(6) Install preformed packing, P/N M83248/1-110, onto drain plug and install plug.
Tighten plug to 40-65 lb in. (4.6-7.3 N·m) of torque.
(7) Safety-wire drain plug to filter bowl and filter bowl to filter head.
(8) Turn on oil supply to gas turbine per packager's manual.
D. Leak-check VG pump/HCU filter as follows:
WARNING
A safety observer shall be stationed adjacent to the enclosure
access.
(1) Open fuel supply valve and make a gas turbine start per packager's manual.
(2) Ensure gas turbine will not be operated above idle.
Change 5 5
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4021 00
(3) Put on protective ear and hand equipment.
(4) Deactivate fire extinguishing system per packager's manual.
(5) Station a safety observer adjacent to the enclosure access.
WARNING
Inlet and exhaust areas of running engines are extremely danger-
ous. Stay clear and wear ear protection.
(6) Enter enclosure. Check for leaks in lube system. Correct leaks as required.
(7) Exit enclosure, secure enclosure access, and activate fire extinguishing system per
packager's manual.
6 Change 5
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4022 00
5WP 4022 00
WORK PACKAGE
TECHNICAL PROCEDURES
PNEUMATIC STARTER SERVICING
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-3 ...... 0
4 Blank ...... 0
Alphabetical Index
Subject Page
Pneumatic Starter Servicing........................................................................................................ 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4022 00
1. Introduction.
This work package contains instructions for servicing the pneumatic starter before installation.
2. Reference Material.
None required.
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Lubricating Oil MIL-L-23699
5. Expendable Material.
Reference GEK 105060, Illustrated Parts Breakdown (IPB).
Nomenclature Part No. Qty
Packing, Preformed J221P906 1
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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GE Industrial AeroDerivative Gas Turbines Volume II
WP 4022 00
6. Pneumatic Starter Servicing.
See figure 1.
NOTE
This procedure is to be accomplished before the pneumatic starter is
installed.
A. Remove reducer from air supply port. Remove and discard preformed packing.
WARNING
Lubricating oil, MIL-PRF-23699F (C/I): Combustible. Do not
inhale, ingest, or let this material touch you. Irritant. Personal
protective equipment required. Use mechanical exhaust ventila-
tion - if not available, use an approved respirator.
B. Pour 12-15 fl oz (350-450 cc) of lubricating oil, MIL-L-23699, into air supply port.
C. Lubricate preformed packing, PN J221P906, with lubricating oil, MIL-L-23699, and
install onto reducer.
D. Install reducer into air supply port. Tighten reducer to 180-200 lb in. (20.3-22.6 N·m)
of torque.
1
Figure 1. Pneumatic Starter Servicing
3/(4 Blank)
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WP 4023 00
0WP 4023 00
WORK PACKAGE
TECHNICAL PROCEDURES
IGNITION SYSTEM FUNCTIONAL CHECK
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-3 ...... 0
4 Blank ...... 0
Alphabetical Index
Subject Page
Ignition System Functional Check.............................................................................................. 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4023 00
1. Introduction.
This work package contains instructions for a functional check of the ignition system.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Troubleshooting Chapter 10
3. Support Equipment.
None required.
4. Consumable Material.
Nomenclature Specification
Safety Cable 736L680G01
Safety Wire (0.032 inch) R297P04 (ALT)
5. Expendable Material.
None required.
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4023 00
6. Ignition System Functional Check.
A. Before inspecting ignition system, perform following:
(1) Shut off main fuel inlet valve per packager's manual.
(2) Shut off electrical power to ignition system per packager's manual.
(3) To clear combustor of any residual fuel, motor gas turbine per packager's manual for
1 minute and allow gas turbine to coast down and stop.
(4) Deactivate fire extinguishing system per packager's manual.
(5) Enter enclosure access per packager's manual. Enclosure door shall remain open.
WARNING
Ignition system shall be inoperative for at least 2 minutes
before disconnecting ignition leads. Ignition system could be
charged with lethal high voltage.
B. Disconnect number one ignition exciter input lead at exciter. Temporarily secure input
lead away from exciter.
C. Turn on electrical power to ignition system (No. 2 ignition exciter energized) per
packager's manual. An audible cracking should be heard when the No. 2 igniter plug
fires.
D. Turn off electrical power to ignition system. Reconnect input lead to exciter and
safety-wire connector.
E. Repeat steps B., C., and D., disconnecting the No. 2 exciter.
F. If an audible noise or cracking is not heard on No. 1 and/or No. 2 igniters, check out
system to isolate problem, and take appropriate corrective action per Volume I,
Chapter 10.
G. Exit enclosure, close enclosure access, turn on electrical power to ignition system, open
main fuel supply valve, and activate fire extinguishing system per packager's manual.
3/(4 Blank)
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WP 4024 00
0WP 4024 00
WORK PACKAGE
TECHNICAL PROCEDURES
VIBRATION MONITORING SYSTEM FUNCTIONAL
CHECK
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-4 ...... 0
Alphabetical Index
Subject Page
Vibration Monitoring System Functional Check ........................................................................ 3
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WP 4024 00
1. Introduction.
This work package contains instructions for a functional check of the vibration monitoring
system.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Accelerometer Replacement WP 1911 00
3. Support Equipment.
Nomenclature Part No.
Megohmmeter Local Purchase
4. Consumable Material.
None required.
5. Expendable Material.
None required.
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WP 4024 00
6. Vibration Monitoring System Functional Check.
WARNING
Gas turbine shall not be operating and shall be verified as
inoperable during inspection period. If possible, lock out
system so it cannot be rotated.
A. Before vibration monitoring system functional check, do the following:
(1) Verify gas turbine will be inoperable during inspection.
(2) Shut off main fuel inlet valve per packager's manual.
(3) Deactivate fire extinguishing system per packager's manual.
(4) Enter enclosure access per packager's manual. Enclosure door must remain open.
(5) Turn on power to purchaser control panel.
CAUTION
Use a small object and light taps when checking accelerometer.
Excessive, hard tapping may damage accelerometer.
B. Check accelerometer by tapping it lightly with a small object (screwdriver handle).
Accelerometer is good if control panel shows an indication of tapping.
NOTE
Control panel must have power turned on or indications will be
incorrect.
C. If accelerometer does not show an indication of tapping, inspect accelerometer for loose
or missing cable clamps, loose mount brackets, and/or loose electrical connections. Make
corrections as required and repeat step B.
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WP 4024 00
D. If accelerometer does not show an indication of tapping after completion of step C.,
perform electrical test of accelerometer as follows:
NOTE
Electrical problems are evident by erratic or no output from the
accelerometer and are indicative of shorted or broken coil
windings, contaminated connector contacts, loose connector, or
damaged leads at the connector backshell.
(1) Using a megohmmeter, or equivalent, verify insulation resistance of accelerometer by
performing resistance check of each connector pin to backshell.
(2) Resistance shall be 100 megohms minimum at 100 Vdc at an ambient temperature
of 60 to 90°F (15 to 32°C). If not, replace accelerometer per WP 1911 00.
E. If accelerometer fails electrical test or fails to operate, replace per WP 1911 00 and repeat
steps B., C., and D.
F. Exit enclosure, close enclosure access, open fuel supply valve, and activate fire
extinguishing system per packager's manual.
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WP 4025 00
0WP 4025 00
WORK PACKAGE
TECHNICAL PROCEDURES
OVERSPEED INSPECTION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-4 ...... 0
Alphabetical Index
Subject Page
Overspeed Conditions Inspection ............................................................................................... 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4025 00
1. Introduction.
This work package contains instructions for overspeed inspection including disposition of the
gas turbine.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
Gas Turbine in Enclosure Replacement WP 3010 00
Gas Turbine Inlet Inspection WP 4010 00
External Engine Cleaning WP 4011 00
Borescope Inspection WP 4015 00
3. Support Equipment.
None required.
4. Consumable Material.
None required.
5. Expendable Material.
None required.
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WP 4025 00
6. Overspeed Conditions Inspection.
CAUTION
If a questionable condition exists, do not attempt to motor or
operate the engine until a thorough investigation of the condition
has been made. Do not repeat hot starts, compressor stalls, load-
shedding, or other problems that initiate emergency shutdowns
or aborted operations without thorough investigation. Failure to
do so may result in undue stress on engine components that may
result in damage and ultimate failure.
NOTE
• The electronic control system low pressure rotor trip point is
4,300 rpm, while the high pressure trip point is 10,711 rpm.
During overspeed events, the rotor speeds can exceed the
control system trip point.
• Following an overspeed trip, the control system transient data
shall be retrieved from the gas turbine electronic control
system. Do not reset the control or attempt another start before
retrieving the data and noting the maximum low pressure rotor
and high pressure rotor speeds during the overspeed event.
A. Following an emergency shutdown for overspeed, retrieve maximum obtained low
pressure rotor and high pressure rotor speeds from electronic control transient data. See
appropriate packager's manual for instructions.
B. Perform overspeed inspection per table 1 (low pressure rotor) and table 2 (high pressure
rotor).
C. Perform gas turbine control system check per appropriate packager's manual.
D. Perform inlet and exhaust inspection per WP 4010 00 and WP 4011 00 or packager's
manual.
E. Borescope low pressure compressor (LPC) and low pressure turbine (LPT) or high
pressure compressor (HPC) and high pressure turbine (HPT) per WP 4015 00.
F. If LPC and LPT or HPC and HPT require teardown, remove gas turbine per WP 3010 00
and return to an authorized depot for teardown and inspection.
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WP 4025 00
Table 1. Low Pressure Rotor Overspeed Inspection and Corrective Action Requirements
Requirements
Control System Inlet and Exhaust LPC & LPT
Condition Check Inspection Teardown
≤4300 RPM X – –
>4300 and X X –
≤4600 RPM
>4600 RPM X – X
Table 2. High Pressure Rotor Overspeed Inspection and Corrective Action Requirements
Requirements
Inlet and
Control System Exhaust HPC & HPT
Condition Check Inspection Borescope HPC Teardown
<11055 RPM X – – –
≥11055 and X X X –
<11202 RPM
≥11202 RPM X – – X
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WP 4026 00
0WP 4026 00
WORK PACKAGE
TECHNICAL PROCEDURES
OVERTEMPERATURE INSPECTION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 6
Page Change Page Change Page Change
No. No. No. No. No. No.
1-6 ...... 0
Alphabetical Index
Subject Page
Overtemperature Conditions Inspection ..................................................................................... 3
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4026 00
1. Introduction.
This work package contains instructions for overtemperature inspection.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
LM6000 System Descriptions Chapter 5
Troubleshooting Chapter 10
Variable Inlet Guide Vane (VIGV) System Check WP 1113 00
Variable Bypass Valve (VBV) System Check WP 1312 00
Variable Stator Vane (VSV) Rigging WP 1411 00
Gas Turbine in Enclosure Removal/Installation WP 3010 00
External Engine Inspection WP 4012 00
Borescope Inspection WP 4015 00
3. Support Equipment.
None required.
4. Consumable Material.
None required.
5. Expendable Material.
None required.
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WP 4026 00
6. Overtemperature Conditions Inspection.
CAUTION
If a questionable condition exists, do not attempt to motor or
operate the engine until a thorough investigation of the condition
has been made. Do not repeat hot starts, compressor stalls, load-
shedding, or other problems that initiate emergency shutdowns
or aborted operations without thorough investigation. Failure to
do so may result in undue stress on engine components that may
result in damage and ultimate failure.
A. Perform overtemperature inspection per table 1.
B. Perform sensor and fuel flow system inspection as follows:
(1) Check Po and Ps3 sensor systems. See appropriate packager's manual (SPAM) to
confirm correct interface location and proper transducer calibration, and check for
sensor line leakage. Correct any abnormal conditions.
(2) Check functionality of XN25 sensors per Chapter 10, TS-28. Check functionality of
T2 and T25 sensors per Chapter 10, TS-27.
(3) Check fuel flow calibration for high fuel flow condition. See appropriate packager's
manual.
C. Perform variable geometry inspection as follows (Chapter 10, TS-23):
(1) Check variable inlet guide vane (VIGV), variable bypass valve (VBV), variable stator
vane (VSV), and torque motor customer interface cables at electrical panel No. 1 for
security. Correct, as required, before restarting engine.
(2) Check electrical connectors, VIGV A, VBV A, and VSV A for security at hydraulic
control unit (HCU). If installed, check VIGV B, VBV B, and VSV B connectors also.
Correct, as required, before restarting engine.
(3) Ensure VSV position indicator (LVDT) indicated 0-42 percent during start. See
appropriate packager's manual to verify correct schedule and proper functioning of
engine control unit (ECU). Perform the following and correct before restarting
engine:
(a) Inspect VSV system mechanical components for damaged, loose, or missing
hardware per WP 4012 00.
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WP 4026 00
Table 1. Overtemperature Inspection and Corrective Action Requirements
T48 During Start-up (Note 2) T48 During Operation
Inspection 1301 to 1301 to 1510 to 1600°F 1683 to 1761 to 1683 to Reference
(Note 1) 1509°F 1509°F 1599°F (872°C) 1760°F (917 1787°F (961 1760°F (917
(705 to (705 to (820 to or more to 960°C) For to 975°C) For to 960°C) For
820°C) For 820°C) For 870°C) more than 5 less than 5 more than 7
less than 40 more than 40 but less than minutes minutes or
seconds seconds 7 minutes >1761°F
(961°C) for
more than 5
minutes
Engine Control X X X X X X X SPAM
System Check
(Note 3)
HPC Stages 1, X X X WP 4015 00
7, and 12
Borescope
Inspection
Combustor and X X X X WP 4015 00
HPT
Borescope
Inspection
LPT Borescope X X WP 4015 00
Inspection
Sensor X X X X X step B.
Inspection
Fuel System X X X X X step B.
Inspection
Variable X X X X X step C.
Geometry
Inspection
Replace X X WP 3010 00
Engine
Note 1 • Record time and temperature in engine log book.
• If maintenance has been performed on the engine, inspect those areas for loose, disconnected, or
improperly inspected connections.
• Borescope engine first to determine engine serviceability.
Note 2 Ensure starter operation meets packager's requirement. Correct as required before restarting engine.
Note 3 • Check ECU for proper schedules and operation.
• If T48 indication system malfunction is found, correct malfunction, restart engine, and check if T48
remains within limits.
• If T48 remains within limits, additional inspections are not required.
• If T48 exceeds limits, shut down engine and perform additional inspections as indicated above.
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WP 4026 00
WARNING
Electrical power shall be off before connecting or
disconnecting electrical connectors. Electricity causes shock,
burns, and death.
(b) Ensure electrical connectors at VSV actuators are secure.
(c) Ensure customer interface cables for VBV/VSV left and right LVDTs, are secure
at electrical panel No. 2.
(d) Perform electrical system wiring check as follows and replace cables as required:
1 Ensure continuity of VSV LVDT electrical cable, left and right, from
appropriate actuator to electrical panel No. 2 per wiring schematics in
Chapter 10.
2 Ensure continuity of VBV/VSV LVDT left and right customer interface
electrical cables from electrical panel No. 2 to ECU interface panel per wiring
schematics in Chapter 10.
3 Ensure continuity of VIGV, VBV, VSV, torque motor A/B, and, if installed,
VIGV, VBV, VSV, and torque motor B/C customer interface electrical cables
from electrical panel No. 1 to ECU interface panel per wiring schematics in
Chapter 10.
4 Ensure continuity of VSV portion of the VIGV, VBV, VSV, torque motor A/B,
and, if installed, VIGV, VBV, VSV, and torque motor B/C electrical cables from
electrical panel No. 1 to HCU per wiring schematics in Chapter 10.
5 Verify ohmic value of VSV torque motor A/B, and, if installed, torque motor
B/C, at HCU connectors No. 4 per troubleshooting tables and wiring schematics
in Chapter 10.
6 Verify ohmic value of VSV actuator LVDTs per troubleshooting tables and
wiring schematics in Chapter 10.
(e) If VSV LVDT indicator is still in error, perform VSV rig check per WP 1411 00.
(4) Ensure VBV LVDT indicated 83-100 percent during start. See appropriate packager's
manual to verify correct schedule and proper functioning of ECU. Perform the following
and correct before restarting engine:
(a) Inspect VBV system mechanical components for damaged, loose, or missing
hardware per WP 4012 00.
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WP 4026 00
(b) Ensure electrical connectors at VBV actuators are secure.
(c) Perform electrical system wiring check as follows and replace cables as required:
1 Ensure continuity of VBV LVDT electrical cables, left and right, from
appropriate actuator to electrical panel No. 2 per wiring schematics in
Chapter 10.
2 Verify ohmic value of the VBV torque motor A/B, and, if installed, torque motor
B/C, at the HCU connectors No. 3 per troubleshooting tables and wiring
schematics in Chapter 10.
3 Verify ohmic value of VBV actuator LVDTs per Chapter 10, troubleshooting
tables and wiring schematics.
(d) If VBV position indicator is still in error, perform VBV rig check per WP 1312 00.
(5) Ensure VIGV LVDT indicated 27-29 percent during start. See appropriate packager's
manual to verify correct schedule and proper functioning of ECU. Perform the following
and correct before restarting engine:
(a) Inspect VIGV system mechanical components for damaged, loose, or missing
hardware per WP 4012 00.
(b) Ensure electrical connectors at VIGV actuators are secure.
(c) Ensure customer interface cables, XN2, VIGV LVDT, left and right, are secure at
electrical panel No. 1.
(d) Perform electrical system wiring check as follows and replace cables as required:
1 Ensure continuity of VIGV electrical cable, left and right, from appropriate
actuator to electrical panel No. 1 per wiring schematics in Chapter 10.
2 Ensure continuity of XN2, VIGV LVDT left and right customer interface
electrical cables from electrical panel No. 1 to ECU interface panel per wiring
schematics in Chapter 10.
3 Verify ohmic value of the VIGV torque motor A/B, and, if installed, torque
motor B/C, at the HCU connectors No. 2 per troubleshooting tables and wiring
schematics in Chapter 10.
4 Verify ohmic value of VIGV actuator LVDTs per troubleshooting tables and
wiring schematics in Chapter 10.
(e) If VIGV position indicator is still in error, perform VIGV rig check per
WP 1113 00.
6
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LM6000 PC GEK 105059
GE Industrial AeroDerivative Gas Turbines Volume II
WP 4027 00
4WP 4027 00
WORK PACKAGE
TECHNICAL PROCEDURES
BEARING SUMP FLOW TESTS
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 8
Page Change Page Change Page Change
No. No. No. No. No. No.
1-7 ...... 6
8 Blank ...... 6
Alphabetical Index
Subject Page
Bearing Sump Flow Tests ........................................................................................................... 3
Change 6 1
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Volume II GE Industrial AeroDerivative Gas Turbines
WP 4027 00
1. Introduction.
This work package contains instructions for air flow testing of the lubrication system.
2. Reference Material.
None required.
3. Support Equipment.
Nomenclature Part No.
Air Flow Tester, Portable - Lube System 9453M62P01
CAUTION
The lube system portable air flow tester, 9453M62P01, must be cali-
brated annually. Failure to do so may result in erroneous readings
and damage to engine bearings.
NOTE
Tool will require electrical power in order to heat air , nitrogen
before final reading 70.5° to 74.0°F (21.4° to 23.3°C), (electrical
supply 110-220 VAC, 50/60 Hz) tool power adapter will convert 220
VAC, 50Hz to 220 VAC, 60 Hz.
4. Consumable Material.
Compressed Air or Nitrogen.
5. Expendable Material.
None required.
2 Change 6
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WP 4027 00
6. Bearing Sump Flow Tests.
WARNING
Do not deform hoses if lowering manifold lower section to gain
clearance for installation of manifold upper section. Failure to
comply may result in hose or fuel nozzle damage.
A. Before performing bearing sump flow tests, perform the following:
(1) Verify gas turbine will be inoperable during test.
(2) Shut off main fuel inlet valve per packager's manual.
(3) Deactivate fire extinguishing system per packager's manual. Enclosure door must remain
open.
(4) Shut off lube oil supply to gas turbine.
B. Deleted.
C. Connect lube flow tester, 9453M62, to a source of clean, dry compressed air or nitrogen and
to connection area to be flow tested. See figures 1 and 2, and table 1. Connect lube flow tool
to electrical supply source.
WARNING
Serious injury can occur when applying compressed air/nitrogen
pressure. Eye protection is required. Relieve pressure before dis-
connecting lines and fittings.
D. Flow test engine frames and gearboxes with clean, dry air at 70.5 to 74°F (21.4 to 23.3°C) at
the tool gage supply pressure of 20 psig (138 kPa). Allow Air/Nitrogen temperature to
stabilize before recording flow data (2-3 minutes). Compare measurements with limits
specified in table 1. Contact CSE or CSM, for engine disposition if sump exceeds flow
limits.
E. Deleted.
2
1
Change 6 3
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WP 4027 00
Table 1. Bearing Sump Flow Test Requirements
Connection Flow Limits Est.
Area (See figure 1) Min Avg Max
A-sump and IGB Front frame aft 14.2 scfm
looking fwd at 8:00
o'clock position. #
-8 to -4 AN reducer
required
B-, C-sump Compressor rear 18.0 scfm 20.0 scfm
frame forward of fuel
nozzles at 8:00
o'clock position
(ALF). #-10 to -4 AN
reducer required (Part
# ANJ919)
D-, E-sump Turbine rear frame at 4.4 scfm
5:00 o'clock position
(ALF). #-8 to -4 AN
reducer required
AGB Gearbox front face. 3.1 scfm
Cap lower line to
TGB disconnected at
5:00 o'clock position
aft looking forward
right side #-6F to
-4M reducer required
TGB Right side of TGB 4.1 scfm
*scfm: square cubic foot per min
4 Change 6
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Figure 1. Engine Connections for Lube Jet Flow Tester, 9453M62 (Sheet 1 of 2)
Change 6 5
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WP 4027 00
Figure 1. Engine Connections for Lube Jet Flow Tester, 9453M62 (Sheet 2 of 2)
6 Change 6
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Figure 2. Lube Jet Flow Tester, 9453M62
Change 6 7/(8 Blank)
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WP 4028 00
0WP 4028 00
WORK PACKAGE
TECHNICAL PROCEDURES
VARIABLE STATOR VANE OFF-SCHEDULE
INSPECTION
(LEVEL 1 MAINTENANCE)
EFFECTIVITY: LM6000 PC GAS TURBINE MODELS
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 4
Page Change Page Change Page Change
No. No. No. No. No. No.
1-4 ...... 0
Alphabetical Index
Subject Page
Variable Stator Vane Off-Schedule Operation Inspection........................................................... 3
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WP 4028 00
1. Introduction.
Engines operated with compressor stators with misassembled, bent, or broken lever arms with
broken connector links, or with actuation rings with elongated lever arm pin holes will result in
an off-schedule vane condition. This condition requires special handling of compressor rotor
blades in the stages adjacent to the vane stage containing the discrepant lever arm or connector
link.
2. Reference Material.
Title Number
Operation & Maintenance Manual GEK 105059
High Pressure Compressor (HPC) Rotor Blades WP 2413 00
Replacement
3. Support Equipment.
Nomenclature Part No.
Gage, Sight - VSV Actuation Arms 2C6962G05
Gage, Sight - VSV Actuation Arms 2C6966G07
Gage, Sight - VSV Stage 5 Actuation 2C8016G02
Arms
4. Consumable Material.
None required.
5. Expendable Material.
None required.
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WP 4028 00
6. Variable Stator Vane Off-Schedule Operation Inspection.
A. Inspect variable stator vane (VSV) lever arms as follows:
(1) Using sight gage tools, determine amount of off-schedule. Use sight gage, 2C6962, for
lever arms assembled to connecting links at the 3:00 and 9:00 o'clock positions. Use
sight gages, 2C6966 and 2C8016, for lever arms assembled to actuation rings.
See figure 1.
(2) Locate the gage over vane tangs and around retaining nut and sleeve. The clear
plexiglass arm extends over the lever arm and has lines scribed at 0 degrees ± 2 degrees,
and ± 4 degrees. The centerline at 0 degrees is scribed on both top and bottom. To
properly view through the gage, the centerlines must line up. The angle of bend is
determined by noting where the center of the pin or rivet is viewed among the scribed
lines.
B. If an off-schedule condition is found, proceed as follows:
(1) Record affected stage and number of degrees of off-schedule condition.
(2) Complete corrective action requirements per table 1.
Table 1. VSV Off-Schedule Corrective Action
Condition Corrective Action
A. Off-schedule is 2 degrees or less No action required
B. Off-schedule is more than 2 degrees, but Replace defective VSV actuation
less than 4 degrees components
C. Off-schedule is 4 degrees or more, or has
broken connector link:
a. Inlet guide vanes Replace two downstream stages of HPC
rotor blades per WP 2413 00
b. Stage 1 vane Replace one upstream and two downstream
stages of HPC rotor blades per WP 2413 00
c. Stages 2 - 5 vanes Replace one upstream and one downstream
stages of HPC rotor blades per WP 2413 00
1
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WP 4028 00
Figure 1. Checking VSV Lever Arms for Circumferential Bending
GE PROPRIETARY INFORMATION - Subject to the restrictions on the cover or first page.
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LM6000 is a registered trademark of the General Electric Company.
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