PowerXpand TM2500+ Gen VI Mobile GTG Set SP-M001 Package Maintenance

GE Aero Energy Products Operations and Maintenance

PACKAGE MAINTENANCE

MAINTENANCE OVERVIEW............................................................................................ 2
On-Condition Maintenance.................................................................................................... 2
On-Site Maintenance ............................................................................................................. 2
Maintenance Schedule ........................................................................................................... 3
Required Lubricants and Consumables ................................................................................. 4

PREVENTIVE MAINTENANCE......................................................................................... 4
Table 2.1 Turbine Engine On-Condition Maintenance Inspection/Check Schedule............. 4
Table 2.2 Generator Inspection Intervals............................................................................... 6
Table 2.3 Ancillary Equipment Maintenance Schedule ........................................................ 7

PREVENTIVE MAINTENANCE PROCEDURES.............................................................. 8

Turbine Compressor Cleaning ............................................................................................... 8
Water Wash, Off-Line ........................................................................................................... 8
Fluid Filter Element Inspection and Replacement............................................................... 10
CO2 Weight and Pressure Check......................................................................................... 12

REQUIRED LUBRICANTS AND CONSUMABLES....................................................... 14

Turbine Lube Oil.................................................................................................................. 14
Generator Lube Oil .............................................................................................................. 14
Hydraulic Fluid .................................................................................................................... 14

TROUBLESHOOTING....................................................................................................... 17
Prime Mover ........................................................................................................................ 17
Generator.............................................................................................................................. 17
Ancillary Equipment............................................................................................................ 17

REPAIRS and ADJUSTMENTS......................................................................................... 18

Turbine................................................................................................................................. 18
Generator.............................................................................................................................. 18
Engine to Generator Alignment ........................................................................................... 18
Ancillary Equipment............................................................................................................ 21

SPARE PARTS.................................................................................................................... 25
Ancillary System Parts List ................................................................................................. 25
 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

MAINTENANCE OVERVIEW

The following maintenance instructions provide a guide to conduct operator-level maintenance of

the GE Energy Model TM2500 MGTG set. Maintenance information for the vendor-supplied
equipment is also provided in this manual.

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

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

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

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

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

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

• Corrective maintenance is described as unscheduled maintenance performed to correct a

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

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

Under the on-condition maintenance philosophy, scheduled maintenance actions requiring

shutdown can be accomplished concurrently at intervals of 4000 hours or 6 months and 8000 hours
or 12 months.

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PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

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

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

On-Site External Maintenance - Level I

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

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

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

malfunction.

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

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

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

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

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

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

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

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

Required Lubricants and Consumables

See Table 2.4, Required Lubricants and Consumables, for recommended list of lubricants and
fluids used on the turbine-generator set. For acceptable equivalents, see vendor-provided
instructions.
PREVENTIVE MAINTENANCE
The schedules in Table 2.1, Turbine Engine On-Condition Maintenance Inspection/Check
Schedule; Table 2.2, Generator Inspection Intervals; and Table 2.3, Ancillary Equipment
Maintenance Schedule describe the recommended inspection intervals for the TM2500 MGTG set.
Recommended maintenance level codes are defined as (1) Level I, Minor Repair; (2) Level II,
Heavy Repair; and (3) Level III, Restoration. Maintenance level codes are assigned based on the
degree of complexity.
Table 2.1 Turbine Engine On-Condition Maintenance Inspection/Check Schedule
Inspection Check Inspection Maint
Item Required Frequency Level Remarks

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

2 General Condition Weekly I Inspect external engine components for

of Engine security of installation.

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

4 Electrical Harness 500 Hours I Check for security; check ignition leads
Leads & Cables and thermocouple harness for burning or
chafing.

5 Control Linkage 500 Hours I Check for freedom of movement, rod end
wear, and security.

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

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

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

or after oil change

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

chapter and section).

10 Fuel Filters 2000 Hours or as required I Check for cleanliness and damage.
by Delta P

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

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

(Continued)

Inspection Check Inspection Maint.

Item Required Frequency Level Remarks

11 Thermocouple Ring 4000 Hours I Check thermocouple calibration.

12 Mechanical Linkages 4000 Hours I Check for wear.

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

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

4000 hours, or as filter.
required by Delta P

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

Supports 4000 hours 12 months or 8000 hours.

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

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

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

4000 hours inspection findings.

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

4000 hours hours, then at 4000 hours.

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

Control 4000 hours necessary.

21 Combustible Gas 6 Months or I Calibrate in accordance with

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

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

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

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

Table 2.2 Generator Inspection Intervals

Inspection Check Inspection Maint.

Item Required Frequency Level Remarks

1 Lube Oil Level Daily I Check reservoir sight gauge for

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

2 Bearing Drains Daily I Check that flow is being

maintained.

3 Vibration Signatures Weekly I Check Bently Nevada gauges for

vibration measurement.

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

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

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

4000 hours, or when
oil is changed

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

rubber-to-metal bond.

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

8000 hours findings.

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

8000 hours gauges, pressure, and temperature
switches.

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

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

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

Table 2.3 Ancillary Equipment Maintenance Schedule

Inspection Check Inspection Maint.

Item Required Frequency Level Remarks

1 General Conditions Daily I General appearance and integrity

of unit.

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

CO2 Weight and Pressure Check.

3 Fluid Filters 3 Months or I Check for blockage.

2000 hours, or as
required by Delta P

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

4000 hours alignment.

5 Thermocouples 6 Months or I Check for secure connections.

4000 hours

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

4000 hours integrity.

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

4000 hours electrical connections.

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

4000 hours, or as
required by Delta P

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

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

10 Ventilation Fan 6 Months or I Replenish bearing lubricant per

Bearings 4000 hours maintenance instructions in Chapter
5.

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

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

12 Optical Flame 6 Months or I Refer to periodic checkout

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

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

Instruments 8000 hours

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

Table 2.3, Ancillary Equipment Maintenance Schedule (Continued)

Inspection Check Inspection Maint.

Item Required Frequency Level Remarks

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

Transducers 8000 hours

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

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

PREVENTIVE MAINTENANCE PROCEDURES

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

Turbine Compressor Cleaning

The water wash provisions are designed to meet the minimum water wash requirements given in
the GE engine manual, and to minimize exposure of service personnel to concentrated cleaning
solvents. For specific guidelines on cleaning scheduling and recommended solvents, see your site-
specific GE engine GEK.

Water Wash, Off-Line

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

CAUTION

DISCONNECT THE DISCHARGE PRESSURE SENSING LINE FROM THE

COMPRESSOR CASING BEFORE PERFORMING OFF-LINE WATER WASH.
FAILURE TO DISCONNECT THE LINE MAY PERMIT SOAP AND WATER TO
ACCUMULATE IN THE LINE, WHICH CAN RESULT IN SUBSEQUENT HOT STARTS
WITH POSSIBLE DAMAGE TO THE TURBINE HOT-SECTION COMPONENTS, OR
CAUSE FALSE SIGNALS FROM THE DISCHARGE PRESSURE TRANSDUCER.

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

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

DANGER

CHEMICALS USED IN COMPRESSOR CLEANING SOLUTION ARE VOLATILE, TOXIC,

AND HIGHLY FLAMMABLE. FOLLOW THE WARNINGS GIVEN IN YOUR GE ENGINE
MANUAL REGARDING THE HANDLING OF CLEANING SOLVENTS. FAILURE TO
FOLLOW GUIDELINES COULD RESULT IN FIRE OR EXPLOSION WITH
SUBSEQUENT INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT.

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

water/antifreeze solution. (See your site-specific GE engine GEK for the mixing ratio.)

NOTICE

DISPOSE OF RESIDUAL WASTEWATER FROM WATER WASH, IN ACCORDANCE

WITH EPA AND LOCAL ENVIRONMENTAL REGULATIONS.

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

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

5. Close tank fill and vent valves.

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

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

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

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

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

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

11. Rinse. Fill tank with 40 gallons of potable water or antifreeze/water solution and repeat
steps 5–9, above, at least three times.

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

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

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

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

NOTICE

IF TURBINE IS TOO WET TO START, CHECK THE CDP TRANSDUCER AND

SENSING LINE FOR WATER. REMOVE ALL WATER PRIOR TO ATTEMPTING A
FIRED START.

IF TURBINE FAILS TO START ON FIRST ATTEMPT, PLACE TURBINE CONTROL

SWITCH IN HI CRANK TO INITIATE AN ADDITIONAL HIGH-SPEED PURGE CYCLE TO
DRY TURBINE SUFFICIENTLY TO PERMIT IGNITION.

16. Start turbine and operate it at idle (gas generator speed of 5000–5500 rpm) for 5 minutes to
dry it.

Fluid Filter Element Inspection and Replacement

DANGER

SYNTHETIC LUBE OIL CONTAINS TRICRESYL PHOSPHATE, WHICH IS HIGHLY

TOXIC AND OPERATES AT HIGH TEMPERATURE AND PRESSURE.

FUEL SYSTEM MAINTENANCE SHOULD BE PERFORMED ONLY WHEN THE

TURBINE IS SHUT DOWN. EXERCISE EXTREME CARE WHEN SERVICING FUEL OR
LUBE OIL SYSTEM. FIRE, EXPLOSION, OR SERIOUS INJURIES COULD OCCUR.

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

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

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

DANGER

WEAR GOGGLES OR SIMILAR EYE PROTECTION WHEN LOOSENING LUBE OIL

SYSTEM FITTINGS, AS RESIDUAL PRESSURE MAY BE PRESENT. DO NOT SMOKE
OR CARRY AN OPEN FLAME OR SOURCE OF SPARKS WHEN SERVICING FUEL
SYSTEM.

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

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

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

NOTICE

FILTER ASSEMBLIES COME IN TWO TYPES. ONE TYPE USES A THROUGH-BOLT

AND/OR NUT ARRANGEMENT TO ATTACH THE FILTER BOWL TO THE FILTER
HEAD. OTHER FILTER ASSEMBLIES INCLUDE A CLAMPING ARRANGEMENT OR A
THREADED FILTER HEAD.

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

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

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

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

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

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

NOTICE

DISPOSE OF CONTAMINATED FLUIDS, IN ACCORDANCE WITH EPA AND LOCAL

ENVIRONMENTAL REGULATIONS.

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

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

CO2 Weight and Pressure Check

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

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

2. To determine the CO2 level in each bottle, use the magnetic float/dipstick indicator as
follows:
a. Remove the chained cap from the liquid level indicator at the top of the CO2 bottle.
b. Lift the level indicator dipstick upward, until a sharp magnetic “tug” is felt on the
dipstick.
c. Read and record the level indicated at the interface between the dipstick and the fixture.
d. Push the dipstick back into the retainer and replace the cap.

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

NOTICE

TO CONVERT THE LEVEL READING TO ITS EQUIVALENT POUNDS OF CO2, SEE

THE CONVERSION CHART ATTACHED TO EACH NEW CO2 BOTTLE. FOR
FURTHER INFORMATION, REFER TO THE CHART IN THE FIRE & GAS
PROTECTION SYSTEM VENDOR MANUAL.

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

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

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

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

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

4. Check the CO2 cylinder charge pressure as follows:

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

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

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

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

REQUIRED LUBRICANTS AND CONSUMABLES

Turbine Lube Oil

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

Generator Lube Oil

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

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

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

Table 2.4 Required Lubricants and Consumables

Specified Required
System Lubricant Address Quantity

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

Caltex RPM California Texas Oil Corp.

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

Mobil Jet Oil II Mobil Sales and Supply Corp.

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

Stauffer Jet II Stauffer Chemical Company

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

Turbine Lube Chevron Research Company

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

Amoco Jet II American Oil Company

500 North Michigan Avenue
Chicago, IL 60611

Sinclair Turbo S Type 2 Atlantic Richfield Co.

875 North Michigan Avenue
Chicago, IL 60611

Atlantic Richfield Co.

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

Exxon Turbo Oil 2380 Exxon Co., USA

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

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 GE Energy
PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

Table 2.4, Required Lubricants and Consumables (Continued)

Specified Required
System Lubricant Address Quantity

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

Castrol Perfecto N.A. Light Stauffer Chemical Company

299 Park Avenue
New York, NY 10017

Mobil DTE Light Mobil Mobil Sales and Supply Corp.

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

Shell Lowtherm 25 Shell Oil Company

Shell Turbo T.32 50 West 50th Street
New York, NY 10020
Hydraulic Fluid Viscosity Ranges

Maximum at Startup 4600 sSu (1000 cSt)

Normal Operating 66–464 sSu (12–100 cSt)

Range

Optimum Operating 81–141 sSu (16–30 cSt)

Range

Minimum Acceptable 60 sSu (10 cSt)

ARCO Duro AW-46 Atlantic Richfield Co. 40 gallons

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

Texaco Rando HDAZ-32 Texaco Incorporated

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

Mobil DTE 25 Mobil Sales & Supply Corp.

150 East 42nd Street
New York, NY 10017

Exxon Nuto H 46 Exxon Co., USA

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

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PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

NOTICE

THESE OILS ARE NOT TO BE CONSIDERED THE ONLY ONES THAT MAY BE USED.
REFER TO THE PERTINENT VENDOR MATERIAL CONTAINED IN THIS MANUAL.
OIL COMPANIES RESERVE THE RIGHT TO REVIEW THEIR SPECIFICATIONS
PERIODICALLY. IT IS ESSENTIAL AND THE CUSTOMER’S RESPONSIBILITY,
THEREFORE, TO VERIFY OIL SPECIFICATIONS WITH THE LOCAL OIL SUPPLIER.

TROUBLESHOOTING

Prime Mover
Troubleshooting procedures for the prime mover are contained in Volume I of the General Electric
On-Site Operation and Maintenance for General Electric TM2500 Gas Generators and Gas
Turbines.

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

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

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TM2500+ Gen VI MGTG Operation and Maintenance Manual

REPAIRS and ADJUSTMENTS

Turbine
Repairs of the LM2500 Turbine Engine are covered in your site-specific GE On-Site Operation
and Maintenance Manual.
Except for the variable stator control, very few adjustments are necessary for the turbine engine.

Generator
Procedures for repairing the FKI BDAX62-170ER AC generator can be found in the FKI
Installation, Operation & Maintenance Manual.
A potential adjustment item is pilot exciter re-magnetization, described in the FKI manual. No
other periodic adjustments of the generator are necessary.
Engine to Generator Alignment
The engine and generator rotor shafts must align with each other before operation. Accurate
alignment extends the service life of the bearings in both machines and ensures efficient, reliable
operation. Under normal operating conditions, optimum axial alignment reduces or eliminates
loading on the thrust bearings in both machines. Laser alignment uses optical measurement
techniques that provide unequaled accuracy and repeatability. Optical measurement reduces many
of the common errors associated with mechanical alignments that are affected by gravity.
Technicians can quickly see graphical representations of the current alignment status and real-time
effects of adjustments made to the turbine-generator unit. Professional reports can easily be
generated by simply downloading laser alignment results to most printers.

NOTICE

ENGINE TO GENERATOR ALIGNMENT IS ACCOMPLISHED DURING SETUP OF THE

MGTG, AND COMPLETE INSTRUCTIONS ARE PROVIDED IN THE INSTALLATION
MANUAL FOR THAT PURPOSE. ALIGNMENT PROCEDURES ARE REPEATED HERE
IN THE EVENT RE-ALIGNMENT BECOMES NECESSARY AT SOME POINT BETWEEN
SETUP AND TEARDOWN, PROVIDING TRAILER LEVELING OR DOCKING HAVE NOT
BEEN DISTURBED. OTHERWISE, PERFORM APPROPRIATE PORTIONS OF THE
MAIN TRAILER SET UP PROCEDURE IN THE INSTALLATION MANUAL BEFORE
PROCEEDING WITH THE ENGINE TO GENERATOR ALIGNMENT.

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PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance

Adjustment Process
The adjustment process starts with the measurement of existing shaft alignments between the
generator and engine, and movement of the engine into position to correct misalignment.
Measurements are made with a ROTALIGN® laser alignment system to identify parallel and
angular offset values of the movable engine shaft as compared to the stationary generator shaft.
Refer to Figure 4.1, Parallel and Angular Offset. All adjustment is accomplished by moving the
engine platform with jackscrews, wedges, and shims, as required to align the engine shaft to the
stationary generator shaft Optimum offset and angular alignment exists when the axes of engine
and generator rotors coincide at normal operating temperatures. In the following procedures, the
term “forward” refers to the direction toward the bell mouth end of the main trailer. GE Aero
Energy Products (GE AEP) Technical Services has the required equipment and personnel
familiar with conducting laser alignments. Please contact your GE AEP Technical Services
regional service office for assistance in contracting their services.
Axial Alignment
Axial loading on the engine thrust bearings can be greatly reduced or eliminated by ensuring that
the engine and generator rotors remain separated at operating temperatures. Incorporate proper
separation by installing the coupling with a pre-stretch that will allow its flexible diaphragm
packs to reach their un-flexed, unloaded states through normal thermal expansion. The forward
thrust capacity of the power turbine thrust bearing is approximately one-third of that in the aft
direction. Therefore, to avoid overloading the bearing in the forward position, use the forward
thrust position as a datum point and calculate the coupling pre-stretch as equaling the algebraic
sum of all thermal expansions from engine cold to engine hot (fully loaded) conditions.
Proceed with axial alignment as follows:
1. Position turbine shaft fully forward.
2. Position generator shaft at the mid-point of its axial travel.
3. Install coupling extension removed for transport (Figure 4.2) and secure turbine end of
extension to the flexible coupling. At the generator end of the extension, temporarily insert
undersized bolts or metal rod through at least two of the extension and generator flange bolt
holes. Bolts or metal rod should be of sufficient diameter to prevent any sagging at the joint,
while allowing the extension to move axially in relation to the generator flange.
4. Using a feeler gauge, measure the gap between the face of the generator coupling flange and
the extension flange. This measurement (pre-stretch) should equal .35 inch.
5. Adjust engine position with clevis fore and aft jacking screws to obtain the required .35 inch
gap. If required amount of adjustment exceeds the range of the jack screws, loosen generator
mounting bolts, and with jack screws in the center of their travel,. move generator axially
with a hydraulic jack until gap is near .35 inch.
6. Tighten generator-mounting bolts and final adjust gap to .35 inch with jack screws.
7. Secure extension flange to generator shaft flange. Repeat this procedure as necessary until
the reading remains unchanged after tightening all fasteners.

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TM2500+ Gen VI MGTG Operation and Maintenance Manual

Preparations for Laser Alignment

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

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

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

Figure 4.1, Parallel and Angular Offset

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Tools and Equipment

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

Table 4.1, Recommended Tools and Equipment

for Alignment

Quantity Description
1 Laser kit with 5-meter cable
1 Magnetic bolthole bracket (PN ALI.2.106)
1 Inside micrometer (STARRETT PN 128BZ) (optional)
1 Dial calipers, 0"–6" (0.001" gradations)
1 Feeler gauge

Desired Parallel and Angular Offsets

Refer to “Alignment Procedure TM2500+ Main Trailer, Initial Setup and Alignment”
(TS00000846) for specific parallel and angular offsets and tolerances for the TM2500+ package.

Ancillary Equipment
Information for repair of the subsystems and components of the unit can be found in Vendor Data
and Drawings.

The following adjustments should be made on an on-condition schedule or as needed to maintain

equipment in proper working order.

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

2. Transducers and Probes — Positioning of probes may need to be adjusted if indications

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

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3. Pressure and Temperature Controllers — Adjustments may need to be made on various

pressure and temperature controllers to keep pressures and temperatures within normal
range. Refer to GE AEP F&IDs contained in Chapter 4 for set points and to Chapter 5 for
details of the various controllers.

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

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

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

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

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

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

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

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

Table 4.3, Level I Maintenance Tools

Nomenclature Quantity

Gauge, Immersion Igniter Plug 1

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

Table 4.4, Level II Maintenance Tools

Nomenclature Quantity

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

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

CAUTION

ANY TEST PROCEDURE THAT CALLS FOR ROTATING MACHINERY TO BE IN

OPERATION SHALL NOT BE ATTEMPTED WITHOUT DIRECT SUPERVISION BY GE
AERO ENERGY PRODUCTS SERVICE TECHNICIANS AND/OR REPRESENTATIVES.
FAILURE TO COMPLY WITH THIS WARNING COULD RESULT IN THE EQUIPMENT
WARRANTY BEING VOIDED.

NOTICE

TEST AND CALIBRATION EQUIPMENT WITH SPECIFICATIONS EQUAL TO OR

BETTER THAN EQUIPMENT LISTED HERE MAY BE SUBSTITUTED. REFER TO
MANUFACTURER-PROVIDED PUBLICATIONS, INCLUDED IN CHAPTER 5 OF THIS
MANUAL, FOR EQUIPMENT SPECIFICATIONS

Nomenclature Part No. Source/Manufacturer

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

Hot-Oil Bath, electrically heated, with Various Various

adjustable thermostatic temperature
control, oil agitator, and calibrated
thermometer (for testing temperature
switches)

Digital Multimeter 8021B Fluke

(two required) 177 Keithley

AC/DC Power Supply 6234A Hewlett-Packard

(two required)

©
Function Generator/ T86671 Woodward Governor Company
Frequency Counter

Volt-ohmmeter, 260 Simpson

20,000 ohms/volt

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

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

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

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PowerXpand TM2500+ Gen VI MGTG Operation and Maintenance
Table 4.5, Test and Calibration Equipment Required for Calibrating the Control System
Sensing Devices (Continued)

Nomenclature Part No. Source/Manufacturer

Jumpers, with insulated alligator Various Various

clips
Ionization Detector Sensitivity SCU-9 Pyrotronics Pyr-A-Larm
Checker
Adapter Kit SAU-2 Pyrotronics Pyr-A-Larm
Megohmmeter 21-158 Biddle (or equivalent)

SPARE PARTS
The TM2500 Turbine-Generator system was engineered, manufactured, and assembled by GE
Energy: With proper scheduled maintenance and careful inspection, this unit is designed to
provide long-term, dependable operation.
GE AEP maintains an extensive inventory of spare parts in Houston, Texas, U.S.A., and at other
facilities around the world. If available at the time of publication, a list of recommended spare
parts will be provided. The list includes parts consumed in the course of performing normal
operation and maintenance, as well as corrective (unscheduled) maintenance. Included in this list
is a recommendation for special support, test, and calibration equipment. The recommended
quantities of spare parts are based on average replacement period per hours of service.
In addition to new parts inventories, GE AEP offers a selected group of components on an
exchange basis. This support program restores the installed unit to operational status in minimum
time and at a considerable cost savings (see Level II, Maintenance Capability).
To procure spare parts through GE AEP, specify the work order number (W.O. 20100), model
number, serial number of the equipment or component, and the quantity of parts to be ordered. To
obtain parts or service, write or call:
GE Aero Energy Products
16415 Jacintoport Blvd.
Houston, Texas 77015
Attention: Service Department
Tel: (281) 457-7555
Fax: (281) 452-7397

Ancillary System Parts List

Part numbers and descriptions for ancillary system components can be obtained by referring to the
GE AEP system drawings contained in this manual and the vendor-furnished publications.

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