NIC 13.20 Rev.01

TECHNICAL BULLETIN
13
NIC 13.20 Rev.01

Feb 06, 2015
LM2500 and PGT25 Gas Turbine Families: Updated Shutdown

and Restart Procedures
Abstract
The purpose of this Technical Bulletin is to inform GE Oil & Gas customers about the sequence modification
required for the entire LM2500 and PGT25 gas turbine families to update the Shutdown and Hot Restart
procedures in accordance with the requirements provided by GE Aviation through the Interim Change
Notes (ICN) and updated Operation & Maintenance manuals (O&M).
This bulletin also introduces software and hardware solutions to mitigate consequences of high load
shutdowns and subsequent restarts.
Reason for Revision

Revised to update restart sequences.
Serviceable Units
LM2500, LM2500+, LM2500+ G4, PGT25, PGT25+, PGT25+ G4 gas turbines in both SAC and DLE configurations
Compliance Category
O Optional
Identifies changes that may be beneficial to some, but not necessarily all, operators.
Accomplishment is at customer's discretion.
M - Maintenance
Identifies maintenance guidelines or best practices for reliable equipment operation.
C - Compliance Required
Identifies the need for action to correct a condition that, if left uncorrected, may result in
reduced equipment reliability or efficiency. Compliance may be required within a
specific operating time.
A - Alert
Failure to comply with the Technical Bulletin could result in equipment or facility
damage. Compliance is mandated within a specific operating time.
S Safety
is
Failure to comply with this Technical Bulletin could result in personal injury. Compliance
mandated within a specific operating time.
Timing Code
1 Prior to Unit Startup / Prior to Continued Operation
2 At First Opportunity / Next shutdown
3 Prior to Operation of Affected System
4 At First Exposure of Component
5 At Scheduled Component Part Repair or Replacement
6 Next Scheduled Outage
7 Optional
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Nuovo Pignone S.r.l. Proprietary Information
The information published in this Technical Bulletin is offered to you by GE in consideration of its ongoing sales and service relationship with
your organization. However, since the operation of your plant involves many factors not within our knowledge, and since operation of the
plant is in your control and ultimate responsibility for its continuing successful operation rests with you, GE specifically disclaims any
responsibility for liability based on claims for damage of any type, i.e. direct, consequential or special that may be alleged to have been
incurred as result of applying this information regardless of whether it is claimed that GE is strictly liable, in breach of contract, in breach of
warranty, negligent, or is in other respects responsible for any alleged injury or damage sustained by your organization as a result of applying
this information. The information contained in this Technical Bulletin is confidential and proprietary. This Bulletin and the information
contained in it are protected by copyright and/or other intellectual property rights. This Bulletin and information are provided for authorized
use only, and may not be used by or disclosed to others without the prior express written consent of Nuovo Pignone S.r.l...
TECHNICAL BULLETIN
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NIC 13.20 Rev.01

Feb 06, 2015
Background
As stated in the O&M manuals, it is critical that the hot restart procedure follows a specific sequence to
avoid major engine damage. The basic objective is to cool the high pressure turbine rotor (HPTR) and high
pressure compressor rotor (HPCR) so blade tips maintain clearance with the more rapidly cooling cases.
Some PGT25 / LM2500 gas generators experienced shaft locking events on a restart attempt following a trip
from high power. The photos below show examples of engine damage caused by an anomalous case
cooling, found excessive with respect to the rotor cooling.
Damages to blades
Damages to cases
SOFTWARE MODIFICATION SHUTDOWN AND HOT RESTART PROCEDURES (MANDATORY)

In order to avoid engine damage, new sequences are now required to allow the engine to cool after a
shutdown or during a hot restart.
The new systems are described below:
A. New Shutdown Procedure
The following types of engine shutdown may occur during engine operation, Normal shutdown and
Emergency shutdown:
Normal Shutdown:
Under normal operating condition, from whatever power the engine is running, during a normal shutdown
the unit is cooled down at minimum load and at idle for 5 minutes. New Normal Shutdown (NS) sequence
adds further cool down motoring @ 2000-2400 rpm that must be initiated no later than 6 (six) minutes after
Gas Generator speed (NGG) < 300 rpm. The engine can be restarted at any time during 15 minutes motoring
at 2000-2400 rpm or if 15 minutes motoring at 2000-2400 rpm is completed. If 2000-2400 rpm motoring is
not initiated within 6 minutes of GG reaching 300 rpm, within the next 4 hour soft start is required*.
*Risk of HPC/HPT rubs if soft start not completed.
2 / 13
This Bulletin and the information contained in it are protected by copyright and/or other intellectual property rights. This Bulletin
and information are provided for authorized use only, and may not be used by or disclosed to others without the prior express written consent
of Nuovo Pignone S.r.l..
TECHNICAL BULLETIN
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NIC 13.20 Rev.01

Feb 06, 2015
Emergency Shutdown:
In an emergency shutdown, the engine can be shut down from any operating power. This can be
accomplished manually or automatically by control system. In this case NO cool down at idle speed is
performed. Depending on the cause of the Emergency Shutdown, the cool down motoring process may or
may not be followed by a motoring period, depending on the following conditions:
After an Emergency Shutdown NO MOTORING (ESN), no further action is allowed.
After an Emergency Shutdown WITH MOTORING (ES):
o If T48 < 1150F for over 8 minutes, Motoring cool down for 15 minutes @ 2000-2400 rpm is
requested.
o
If T48 > 1150 F or T48 < 1150F for less than 8 minutes, Motoring cool down for 15 minutes
@ 1000-1200 rpm is requested.
B. New Restart Procedures

CAUTION: IT IS UNDERSTOOD THAT THE CAUSE OF THE TRIP MUST BE DETERMINED AND RESOLVED PRIOR TO
RESTARTING THE ENGINE.
Restart may be initiated at any time if the prior shutdown sequence was normal.
Definitions:
4 HOURS LOCKOUT: Control logic that forces an engine stop for 4 hours after an emergency shutdown at
high power.
SOFT START: Hardware system that permits performing the restart procedure during lockout period.
The procedure is as follow:
Verify HP rotor is free by manually applying less than 45 ft-lb (61 N*m) of torque on the AGB starter
shaft.
If rotation is verified by the speed signal, then dry-motor the rotor at HP rotor speed of 1000-1200
rpm for 20 minutes.
After completion of 20 minutes of 1000-1200 rpm dry motoring, immediately proceed with a normal
purge and start cycle.
After any type of emergency shutdown, it is only possible to immediately restart the engine by following the
applicable start sequences and procedures.
B.1 Restart after Normal Shutdown
After a NS, a normal start can be executed at any time after motoring @ 2000-2400 rpm is initiated or upon
completion of 15 minutes of motoring. If engine motoring is not initiated within 6 minutes of GG reaching
300 rpm, during the next 4 hours SOFT START procedure is required.
3 / 13
TECHNICAL BULLETIN
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NIC 13.20 Rev.01

Feb 06, 2015
B.2 Restart after Emergency Shutdown with Motoring (ES)
Restart after low power ES (T48<1150F for over 8 minutes)
After a low power ES, a normal start can be executed at any time after motoring @ 2000-2400 rpm is
initiated or upon completion of 15 minutes of motoring. If engine start or motoring is not initiated within 6
minutes of GG reaching 300 rpm, during the next 4 hours SOFT START procedure is required.
Restart after high power ES (T48>1150F or T48<1150F for less than 8 minutes)
After any high power ES (T48 > 1150F (621.1C)), a 15 minutes motoring at 1200 rpm is executed. During the
next 4 hours, only soft start is allowed.
CAUTION: BY-PASSING THIS LOGIC AND CRANKING THE HP ROTOR MAY RESULT IN SEVERE HP COMPRESSOR
RUBS AND MAY DAMAGE THE COMPRESSOR BLADES AND VANES.
B.3 Restart after Emergency Shutdown with NO Motoring (ESN)
In this case, the logic control system forces 4 HOURS LOCKOUT and restart of the engine can be
accomplished only by following the SOFT START procedure.
If mandatory modifications stated above are not applied (motoring sequences not updated), the engine must
be considered to be in 4 HOURS LOCKOUT status after every type of shutdown (NS, ES, ESN), as per latest O&M
requirements.
Figure 1: Shutdown and Restart after Normal Shutdown (any T48)
4 / 13
TECHNICAL BULLETIN
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NIC 13.20 Rev.01

Feb 06, 2015
Figure 2: Shutdown and Restart after low power ES (T48<1150F)
Figure 3: Shutdown and Restart after high power Emergency Shutdown T48>1150F (621.1C) Soft Start (1)
5 / 13
TECHNICAL BULLETIN
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NIC 13.20 Rev.01

Feb 06, 2015
Figure 4: Restart after any ESN Soft Start (2)

HARDWARE AND SOFTWARE IMPROVEMENT (OPTIONAL)
To mitigate the impact on the availability of units due to the modification of the previous sequences, GE Oil &
Gas has developed alternative ways to speed up the restart process by acting on the hydraulic starting
system (AUTOMATIC LOCKED ROTOR CHECK) and by introducing a new electrical device (SLOW MOTORING).
The proposed hardware modification can be considered as optional.
These systems can be implemented separately, they are mutually independent and they have different
functions.
1. Automatic Locked Rotor Check (SOFT START):
NOTE: Automatic Locked Rotor Check procedure is not reducing the list of emergency shutdown, but it is an
automated procedure to perform the locked rotor check. This will reduce the 4 hour lock out time, allowing a
starting tentative as soon as the cause of the emergency shutdown has been solved.
This device is a hardware modification to automatically apply the SOFT START procedure. It allows verifying
if the HP rotor is free, by applying less than 45 ft-lb (61 Nm) of torque to the AGB starter shaft. This system is
only applicable to hydraulic starting system and NOT to pneumatic starting systems.
A solenoid damp valve, combined with a very slow flow ramp-up from hydraulic pump achieves a slowly
increasing differential pressure across the hydraulic starter, resulting in a slow increase in torque at the
hydraulic starter output shaft. Dedicated pressure transmitters are used to verify the actual differential
pressure needed to operate the starter. By comparing it to the maximum allowed value, it is possible to
verify the maximum torque requirement.
6 / 13
TECHNICAL BULLETIN
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NIC 13.20 Rev.01

Feb 06, 2015
The solution needs to be verified site by site since the presence of different pump stroke limitations, isolation
valves and/or small cooling systems can impact the items to be substituted or energized.
There are two possible options:
Closed loop starting system

This is the typical version installed in the enclosure of older package design, where the cooler and the tank
are dedicated only to the starting system. A variable flow HP pump takes the oil directly from the starter
return line, and delivers it back to the starter inlet. The usual closed loop starting system included
manometers in place of pressure transmitters, and a solenoid valve was not used.
In this configuration, to implement the solution, the bypass Solenoid Damp Valve and pressure transmitters
(instead of manometers) are to be added to existing packages and a change in logic is needed to introduce
the Locked Rotor Check (Soft Start) logic.
Open loop starting system

The typical version installed in the Package Redesign enclosures is also present in some older packages. The
pump takes oil directly from the shared oil circuit used on the Gas Turbine / load equipment. A small pilot
pump is present in place of the make-up pump. Oil is sent back to the main circuit and common cooler/tank.
In this configuration, a by-pass valve and pressure transmitter are already present in all package redesign
version enclosures (open loop). Only a change in logic is needed to introduce Locked Rotor Check (Soft Start)
logic.
7 / 13
TECHNICAL BULLETIN
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NIC 13.20 Rev.01

Feb 06, 2015
2.
Slow Motoring
NOTE: Pony Motor device is increasing engine availability, since the rotor will never stop. This will reduce the
4 hour lock out time, allowing a successful restart as soon as the cause of the emergency shutdown has
been solved.
Slow Motoring (or Pony Motor) is a hardware/software modification to avoid the 4 HOURS LOCKOUT
sequence and shutdown motoring. The rotor is kept turning at slow speed (100 rpm) by a worm gearbox
driven by an AC motor and connected to the Accessory Gear Box through a specially designed clutch. After
any shutdown (ES, ESN, failed NS), slow rotation must be initiated as soon as the driven equipment comes to
rest but no longer than 6 minutes after Gas Generator Speed (NGG) < 300 rpm, otherwise engine must be
considered in 4 HOURS LOCKOUT configuration. Slow rotation at about 100 rpm can be continuously done
for 4 hours. During this period a normal start sequence can be performed at any time skipping free HP
rotation check. After 4 hours of slow rotation a normal start can be accomplished.
The device can be powered by either plant AC, a plant battery pack (DC) or a dedicated battery pack (DC). An
inverter is required to provide AC power to the electric motor if DC is used.
Main Features:
Low power (~550W) aluminum casing AC motor connected to

Auxiliary Gearbox (AGB) through a special gearbox
Lightweight components to minimize loads on AGB (complies
with GE Aero Energy requirements)
Suitable for operation in ATEX Zone I explosive atmosphere
Double protections (electronic torque feedback + mechanical
torque limiter) to limit the transmissible torque within GE Aero
Energy safe limits
Self-disengagement of the device at engine restart
Power supply from battery pack + Inverter to prevent rotor lock
in the event of AC loss (optional).
GE Oil & Gas patented
Required utilities:
Electric Motor: 550W 50Hz 400VAC or 60Hz 440VAC

Linear Actuator: 80W 24VDC
Position Probes: 200 mA 24VDC
The system can be supplied with a DC UCP and inverter (optional), to back-up in case of loss of AC in the
plant.
To increase engine availability, Pony Motor can be used after an Emergency Shutdown MOTORING (ES) when
T48 > 1150F (621.1C), in place of the 15 minutes motoring @ 1000-1200 rpm. This will allow engine to be
restarted anytime through normal start sequence while Pony Motor is ON. This will save the 15 minutes of
the motoring and the 20 minutes of the soft start sequence time.
NOTE: Pony Motor could be applied also after a NS or a ES from T48 < 1150F (621.1C). This is not
recommended, though, because 15 minutes motoring @ 2000-2400 rpm (related to the proper shutdown
logic) will clear any residual temperature gradient once and for all, without leaving energized parts in the
engine.
8 / 13
TECHNICAL BULLETIN
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NIC 13.20 Rev.01

Feb 06, 2015
Figure 5: Restart after any kind of shutdown (NS, ES, ESN) using Pony Motor
Figure 6. Shutdown and Restart General Flowchart

9 / 13
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Feb 06, 2015
A list of the Emergency Shutdown No Motoring events can be found in Table 1. For all these events, motoring
is not allowed, and 4 HOURS LOCKOUT is mandatory if a mitigation procedure (soft start or pony motor) is
not applied. It is understood that the cause of the trip must be determined and resolved prior to restarting
the engine. Consult the table below for the applicability of the mitigation process.
CAUTION: use of Pony Motor device is allowed after any emergency shutdown MOTORING (ES), and after
most of the emergency shutdown NO MOTORING (ESN) (see Table 1). While Pony Motor is ON, unit can be
restarted anytime through normal start sequence, but only after the cause of the emergency shutdown has
been captured and solved.
ESN trigger
1. HP rotor over speed trip.
2. HP rotor back-up over speed trip.
EHS related
N
N
Pony Motor ON
NO
NO
NO
3. Loss of both HP rotor magnetic speed pick-ups
As soon as the speed pickups are not

available
4. Power turbine rotor over speed trip.

5. Power turbine rotor back-up over speed trip.
6. Loss of both PT rotor magnetic speed pick-ups
7. Axial compressor stall detected.
8. Very high gas generator vibration.
9. Very high power turbine vibration.
10. Loss of synthetic lube oil header pressure sensor
11. Very low synthetic lube oil header pressure.
12. Loss of power turbine lube oil header pressure
sensor.
N
N
N
N
N
N
N
N
YES
YES
YES
YES
YES
YES
YES
YES
YES
13. Starter clutch over speed shutdown (Hilliard clutches

only).
If clutch is really failed, pony will not

have enough torque to run anyway
14. Starter clutch re-engaged shutdown (Hilliard

clutches only).
If clutch is really failed, pony will not

have enough torque to run anyway
15. Panel emergency shutdown no motoring push

button.
16. Customer emergency shutdown no motoring (if any).
17.a. Very high gas level detected (inside turbine
enclosure or) in the air inlet filter.
17.b. Very high gas level detected inside turbine
enclosure (or in the air inlet filter).
18. Gas turbine enclosure fire detected.
19. Gas turbine enclosure fire extinguisher manual
discharge.
20. Loss of gas turbine enclosure ventilation. Not
certified devices power supply cut-out.
21. Process gas depressurized emergency shutdown.
22. Very high axial displacement load gearbox and
driven equipment.
23. Very high radial vibration load gearbox and driven
equipment (at NPT speed less than 300 rpm if not
latched in deviation from API670).
Customer
specific
Customer
specific
YES
YES
Depending on customer
Depending on customer
NO
NO
NO
NO
YES
YES
YES
YES
Table 1: List of Emergency Shutdown NO motoring (ESN) conditions

10 / 13
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NIC 13.20 Rev.01

Feb 06, 2015
Recommendations
GE Oil & Gas recommends updating Shutdown and Hot Restart procedures in accordance with the
requirements provided by GE Aviation through the updated Operation & Maintenance manuals (O&M).
The new sequence requirements are mandatory for all existing families of LM2500/PGT25 Gas Generator
units, both new and in service. They need to be included in units currently in service, retrofitting or
upgrading.
A summary of requirements is listed in the following table:
Requirement
Mandatory
15 minute motoring @ 2000-2400 after Normal Shutdown.

Software upgrade needed.
15 minutes motoring @ 2000-2400 rpm after Emergency Shutdown
if T48 < 1150F (621.1C) for over 8 minutes.
15 minutes motoring @ 1000-1200 rpm after Emergency Shutdown
if T48 > 1150F (621.1C) or T48 < 1150F for less than 8 minutes.
Hot restart sequence after ES T48>1150F (621C) or after ESN (20
minutes slow crank @ 1000-1200,).
Automatic locked rotor check (Soft start)
(verify if the HP rotor is free, by applying less than 45 ft-lb)
Software and hardware upgrade needed.
Slow motoring (Pony motor)
(Rotor is kept turning at slow speed ~100 rpm).
Software and hardware upgrade needed.
Optional
to reduce 4 hours
lock out time
X
X
X
X
X
X
Table 2: Summary of Requirements

This NIC supersedes both NIC 05.38 Rev. 01 and NIC 05.27 Rev. 01 that henceforth will be marked as
obsolete.
GE Oil & Gas is neither responsible nor liable for property damage arising from the failure to follow all the
procedures and guidelines listed in this document and its attachments.
11 / 13
TECHNICAL BULLETIN
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NIC 13.20 Rev.01

Feb 06, 2015
Planning Information
Manpower skills
SOFTWARE MODIFICATION:
One qualified technician for one day shift (with the updated software available). The Software
update must be evaluated and performed by GE Oil & Gas Headquarters based on the specific
customer configuration.
SOFT START hardware modification:
Each modification must be evaluated by GE Oil & Gas Headquarter based on customer hardware
configuration.
SLOW MOTOR hardware/software modification:
Each modification must be evaluated GE Oil & Gas Headquarter based on hardware customer
configuration
Parts
SOFT START:
Part number list must be evaluated by GE Oil & Gas Headquarter based on customer hardware
configuration and requests
SLOW MOTOR:
Part number list must be evaluated by GE Oil & Gas Headquarter based on customer hardware
configuration and requests
Special Tooling
N/A
Reference Documents
O&M manuals references ICNs

Ref.
LM2500-IND-GEK103089-044
LM2500-IND-GEK97310-144
LM2500-IND-GEK105048-051
LM2500-IND-GEK105054-048
LM2500-IND-GEK112767-036
LM2500-IND-GEK112859-032
GG Model
LM2500 DLE
LM2500 SAC
LM2500+ DLE
LM2500+ SAC
LM2500+G4 DLE
LM2500+G4 SAC
Scope of work
The mandatory software update in accordance with the requirements provided by GE Aviation must be
evaluated and performed by GE Oil & Gas Headquarters based on the specific customer configuration.
The optional updates (Soft Restart and Slow Motoring) must be evaluated and performed by GE Oil & Gas
Headquarters based on the specific customer configuration.
Note: In order to keep the GE Oil & Gas global installed fleet database updated, it is kindly requested that the
COMPLIANCE RECORD and USER SATISFACTION SURVEY be completed and sent to the addresses specified in the forms.
12 / 13
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NIC 13.20 Rev.01

Feb 06, 2015
Contacts
For units under warranty or covered under a Contractual Service Agreement (CSA) please refer to your GE
Oil & Gas Project Manager.
For technical questions or application and commercial requests please contact:
GE Oil & Gas
Customer Service Center
Via Felice Matteucci, 2
50127 Florence, Italy
e-Mail: [email protected]
Web: http://www.geoilandgas.com/businesses/ge_oilandgas/en/prod_serv/serv/cust_serv.htm
Phone: +39 055 427 2500
Fax: +39 055 423 2800
Please specify the Unit Serial Number and Technical Bulletin associated with the request and whether
the request is technical or commercial.
To directly access and download GE Oil & Gas Technical Bulletins published on your fleet or to subscribe to
our Technical Bulletin e-mail notification service, please visit the Technical Updates Portal:
http://www.geoilandgas.com/businesses/ge_oilandgas/en/about/technical_bulletins.htm
This online tool is available only to registered GE customers. Please refer to NIC 07.37.SL for any additional
information.
The recommendations contained in this Technical Bulletin are for information only. Unless otherwise
indicated in a Contractual Service Agreement (CSA) in force between the parties, all costs associated with
implementation of the recommendations are the Customers responsibility.
Warranty issues will be handled as per the terms of the contract.
13 / 13
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NOTE: To directly access and download GE Oil & Gas Technical Bulletins published on your equipment and to
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TECHNICAL BULLETIN

NIC 13.20 Rev.01

LM2500 and PGT25 Gas Turbine Families: Updated Shutdown

Reason for Revision

Identifies maintenance guidelines or best practices for reliable equipment operation.

Nuovo Pignone S.r.l. Proprietary Information

NIC 13.20 Rev.01

SOFTWARE MODIFICATION SHUTDOWN AND HOT RESTART PROCEDURES (MANDATORY)

NIC 13.20 Rev.01

B. New Restart Procedures

NIC 13.20 Rev.01

Figure 1: Shutdown and Restart after Normal Shutdown (any T48)

NIC 13.20 Rev.01

Figure 2: Shutdown and Restart after low power ES (T48<1150F)

NIC 13.20 Rev.01

Figure 4: Restart after any ESN Soft Start (2)

NIC 13.20 Rev.01

Closed loop starting system

Open loop starting system

NIC 13.20 Rev.01

Low power (~550W) aluminum casing AC motor connected to

Electric Motor: 550W 50Hz 400VAC or 60Hz 440VAC

NIC 13.20 Rev.01

Figure 6. Shutdown and Restart General Flowchart

NIC 13.20 Rev.01

3. Loss of both HP rotor magnetic speed pick-ups

As soon as the speed pickups are not

4. Power turbine rotor over speed trip.

13. Starter clutch over speed shutdown (Hilliard clutches

If clutch is really failed, pony will not

14. Starter clutch re-engaged shutdown (Hilliard

If clutch is really failed, pony will not

15. Panel emergency shutdown no motoring push

Table 1: List of Emergency Shutdown NO motoring (ESN) conditions

NIC 13.20 Rev.01

15 minute motoring @ 2000-2400 after Normal Shutdown.

Table 2: Summary of Requirements

NIC 13.20 Rev.01

O&M manuals references ICNs

NIC 13.20 Rev.01

Technical Update Communication

TECHNICAL BULLETIN COMPLIANCE RECORD

Customer Contact Information

Technical Bulletin Applied:

Technical Bulletin Completion Date:

GE OIL & GAS Technical Update Communication

Technical Update Communication

USER SATISFACTION SURVEY

GE OIL & GAS Technical Update Communication

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