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VOLUME I
CHAPTER 4
GENERAL OPERATION AND TROUBLESHOOTING
Change 2 4-1
a. The requirements for gas turbine/gas work on the lube system, the lube oil condition
generator lubricating oil are provided in and storage system, and any circuits that sup-
document MID-TD-0000-6, included in ply the control valves should be circulated,
Appendix A. Type II oil MIL-PRF-23699, is flushed, etc. to ensure cleanliness prior to the
the preferred lubricant for the LM2500 DLE engine being connected.
gas turbine. This type of synthetic oil has a
coking temperature advantage of 20°F to 50°F NOTE
(11°C to 28°C) over type I (MIL-PRF-7808). Following this flushing, the system fil-
Improved film effectiveness of ter elements should be removed and
MIL-PRF-23699 at higher temperatures also replaced to avoid engine
improves bearing life. Type I lubricant is not contamination.
recommended for general use in the LM2500
DLE. In applications where very low tempera- f. In the event of a failure during site
ture starting capability is required, Type I oil operation that involves the engine lube system,
may be used provided the ambient temperature the system shall be disconnected, drained, and
is consistently lower than 68°F (19.9°C). Any cleaned as described in the preceding step.
use of type I oil requires approval of M&IED This procedure should be followed whether the
for the specific site. engine is removed and replaced or repaired on
site.
b. Minimum temperature at start is 20ºF
(-6.7°C) for lubricating oil, MIL-PRF-23699 g. Engine oil is filtered to 10 microme-
(type II), and -20°F (-28.9°C) for ters, nominal.
MIL-PRF-7808 (type I).
4-6 NOX SUPPRESSION WATER
c. Steady-state operations and transients REQUIREMENT
above idle should be restricted until oil supply
temperature is at least 90°F (32.2°C). 4-6.1 General. The requirements for
water injected for NOx suppression are pro-
d. Mixing different (type I vs. II) oil is not vided in document MID-TD-0000-3, included
allowed. If mixing does occur, the tank should in Appendix A.
be drained, flushed, and serviced as soon as
possible. Also, changing oil type requires 4-7 INITIAL OPERATION
draining and flushing. Topping off when
changing oil brands of the same type is pre- 4-7.1 General. Initial operational period
ferred method, but indiscriminate changing is is that period of operation immediately follow-
not recommended. ing engine replacement or major maintenance
on the system.
CAUTION
FAILURE TO PROPERLY MAIN-
TAIN A CLEAN LUBE SYSTEM
COULD RESULT IN PREMATURE
FAILURE OF THE GAS TURBINE
OR COMPONENTS.
e. Before the initial motoring and start of
an LM2500 in new installation or following
4-2 Change 2
4-11.1 Restart Within 10 Minutes After (1) Remove maintenance drive pad
Shutdown. If circumstance permits the shut- cover from AGB. Confirm free rotation of the
down problem to be cleared within 10 minutes GG rotor by slowing rotating the manual drive
or less, and gas generator speed is less than input shaft one (1) turn clockwise (CW), aft
300 RPM, the restart procedure is as follows: looking forward.
a. Start the restart timer and initiate a (2) If no rotor lock or drag is noted,
manual restart purge. Reset all other timers as quickly rotate the manual drive input shaft one
required. (1) additional turn CW, noting any drag or
b. Energize the starter to motor the gas rotor/stator contact either by feel through the
generator rotor to a speed of 2000-2400 RPM wrench handle, or audibly as the rotor slows to
for a minimum of 5 minutes. If the gas genera- a stop.
tor rotor rotates freely, a normal start may be
allowed. (3) If rotor locks or drags during rota-
tion, do not apply additional torque at the man-
c. If a start is not immediately required, ual drive input. Wait 5 minutes and repeat
the motoring will preserve the capability to attempt to rotate manual drive input shaft.
restart the engine any time after the fault has Continue attempts to rotate manual drive on
been cleared. 5-minute intervals as needed until the required
rotation can be completed with no rotor drag.
4-11.2 Restart More Than 10 Minutes
After Shutdown. If motoring or restart was NOTE
not performed within 10 minutes after gas gen-
erator speed coasted below 300 RPM, the con- Repeating the free rotation check at the
trol system must prevent motoring or starting manual drive input shaft on 10-minute
for four hours. intervals during the shutdown period
minimizes the probability of rotor
a. After four hours the normal start lockup.
sequence can be initiated.
(4) When time is less than or equal to
4-11.2.1 Alternative Start Procedure Dur- 10 minutes before dry motoring is to begin,
ing a Four-Hour Window After a Hot Shut- perform a final free rotation check as described
down. If the GT is not restarted or cool-down in substep 2 to verify no rotor lock or drag is
motoring has not begun within 10 minutes noted.
after the high-pressure rotor has coasted to
below 300 rpm following an emergency shut- (5) Replace manual drive pad cover.
down, or trip from T5.4 greater than 1150°F
(621.1°C), the four-hour lockout period may (6) Exit package, following all safety
be avoided as follows: and lockout/tagout requirements.
a. If Automatic Rotor Free Check System (7) Engage starter and dry-motor GG
is not in place, ensure all safety and lockout/ at HP rotor speed of 1000-1200 rpm for 20
tagout requirements have been met prior to minutes.
entering the package and performing any of
the following steps:
4-4 Change 2
Change 2 4-5
d. Check supply pressure to starter. Refer j. If gas generator will not turn after wait-
to packager’s manual. If necessary, adjust sup- ing three hours, and starter will not turn it,
ply pressure to starter. troubleshoot gearbox per paragraph 4.12-24.
4-6 Change 2
Fault Paragraph
No indication of gas generator rotation 4-12.2
Gas generator fails to reach 1100 rpm in 20 seconds during start or fails 4-12.3
to reach 2100 rpm during motoring.
High or low starting fuel manifold pressure 4-12.4
Gas generator fails to light off 4-12.5
Hot start: starting T5.4 exceeds limit 4-12.6
Gas generator fails to reach idle or slow acceleration to idle 4-12.7
Gas generator idle rpm not within limits 4-12.8
Gas generator speed unstable/hunting 4-12.9
Slow acceleration 4-12.10
Compressor stall or high T5.4 during acceleration or deceleration 4-12.11
High GG speed, low power, low T5.4 4-12.12
High GG speed, low power, high T5.4 4-12.13
Performance loss greater than 25°F (17°C) 4-12.14
High vibrations - gas generator 4-12.15
High Vibrations - power turbine 4-12.16
Variable stator vane system malfunction 4-12.17
High or low lube oil pressure 4-12.18
High scavenge oil temperature 4-12.19
High lube oil consumption 4-12.20
Incorrect or fluctuating T5.4 4-12.21
Variable stator control system problems 4-12.22
Gas generator speed instrumentation problems 4-12.23
Gearbox problems 4-12.24
Ignition system problems 4-12.25
Start stall problems 4-12.26
Power turbine inlet T5.4 thermocouple system problems 4-12.27
Power turbine inlet T5.4 thermocouple system temperature spread 4-12.27A
troubleshooting procedure
Power turbine tranducer motional pickup troubleshooting 4-12.29
Change 2 4-7
4-8 Change 2
c. Check fuel supply pressure to fuel con- d. Check fuel control per packager’s
trol unit. If not within operating limits, adjust manual.
pressure regulating valve per packager’s
manual. e. Check variable stator vane scheduling
per WP 118 00 or SWP 118 01.
d. If start is hot at light-off and during
first portion of start cycle, adjust minimum 4-12.9 Gas Generator Speed Unstable/
fuel flow per packager’s manual to decrease Hunting.
fuel manifold pressure during initial lightoff.
a. Check fuel control per packager’s man-
e. If start is hot during acceleration, after ual and adjust as required.
lightoff, or if adjustment in step d is not effec-
tive, adjust acceleration schedule to decrease b. Check variable stator vane scheduling
fuel flow rate during acceleration period per to make sure vanes open during acceleration
packager’s manual. per WP 118 00 or SWP 118 01.
a. Check instrumentation. Replace faulty d. Check for damage to high pressure tur-
indicator. bine blades or vanes.
b. Check fuel flow and/or pressure. e. Check for damage to combustor or tur-
Adjust per packager’s manual, if required. bine mid frame liner.
Change 2 4-9
4-12.13 High Gas Generator Speed, Low d. Using vibration measuring instrument
Power, High T5.4. High gas generator speed, with frequency-scanning type filter, determine
high gas generator exhaust gas temperature, predominant frequency. If it is same as gas
and low output power, are symptoms of a generator speed, problem probably lies in gas
fouled (dirty) compressor or misrigging of generator. Shut down gas generator, and listen
variable stator control system. Check variable for unusual noises during coastdown. Inspect
stator control system to determine if it is on compressor inlet by removing inlet screen, and
schedule per WP 118 00 or SWP 118 01. If inspect remainder of gas generator by using
not, adjust per WP 118 00 or SWP 118 01. If borescope.
on schedule, water wash compressor per
Chapter 5. e. Inspect oil scavenge screens and mag-
netic plugs in lube scavenge pump.
4-12.14 Performance Loss Greater Than
25°F (17°C). f. Water wash compressor if inspection
reveals dirty blades and vanes.
a. Water wash compressor per Chapter 5.
4-12.16 High Vibrations in Power Turbine.
b. Check variable stator vanes to make
sure they move during acceleration and decel- a. Check that vibration instrument and its
eration. Troubleshoot per paragraph 4-12.22. wiring are operating properly.
c. Perform borescope inspection for inter- b. Check that vibration pickup is securely
nal damage per Chapter 5. mounted.
4-10 Change 2
e. Inspect oil scavenge screens and mag- a. If during steady state or constant power
netic plugs in lube scavenge pump. operation a shift in the difference between lube
supply temperature and any scavenge oil tem-
f. Check high speed coupling and driven perature exceeding 30°F (17°C) is observed,
load for excessive vibrations. the engine should be shut down for further
investigation and troubleshooting of the lube
4-12.17 Variable Stator Vane (VSV) scavenge system.
System Malfunction. Refer to
paragraph 4-12.22. b. If the high scavenge oil temperature
reading is observed on all scavenge lines,
4-12.18 High or Low Lube Oil Pressure. check oil supply temperature to see if it is
high, and adjust cooling system if necessary.
NOTE Also, check oil tank level; add oil if necessary.
Oil pressure is a function of gas gener-
ator speed and supply oil temperature. c. Check lube scavenge screen for partic-
Refer to Chapter 5 for temperature ular sump which is reading high.
correction factors.
d. If one high scavenge oil temperature
a. If oil supply pressure is high, check for reading is observed, switch instrumentation
obstructions in oil supply line between oil leads in panel to determine if problem is in
pressure tap and bearing oil jets. Also, check instrument. Also check to see if problem is in
for failed lube/scavenge pump. sensor by switching sensors or switching leads
at sensors.
b. If oil supply pressure is low, check sup-
ply oil filters for cleanliness and supply lines e. If this does not correct problem, check
for leaks. If low pressure persists, replace lube/ oil supply line to, and vent line from, that bear-
scavenge pump. ing area for leakage and obstructions.
c. If scavenge oil pressure is high, check f. Check for failed section in lube and
scavenge oil filters for cleanliness. Also check scavenge pump on aft face of accessory
anti-static check valve and other downstream gearbox.
components for sticking, fouling, or contami-
nation. Maximum permissible scavenge oil
pressure is 20 psig (138 kPa).
Change 2 4-11
d. Check color of exhaust gas from gas (b) If actuator will not move,
generator. It should be clear. A significant disconnect actuators from mechanism and
internal oil leak may be reflected by white operate actuators. Pressure required to operate
smoke at lower rpm and by black/brown actuators should be less than 10 psig
smoke at high rpm. (69.0 kPa). If pressure required is greater than
15 psig (103 kPa), replace actuator(s).
e. Check combined oil drain line from B
and C sump seals. Maximum oil leakage from (c) If actuators are all right,
this line is 7 cc/hr. Check oil drain located reconnect them to mechanism, and measure
under accessory gearbox. Leakage in this line rod end and head end pressures on a 500 psi
comes from AGB pad drains, starter drain, (3450 kPa) gage. Pressure required to open
variable vane actuators and lube and scavenge stators should not exceed 200 psig (1380 kPa),
pump. Maximum oil leakage from this line is 5 and should not exceed 200 psig (1380 kPa) to
cc/hr. If leakage is excessive, disconnect drain close them. If pressure required exceeds limits,
line at each area and isolate source and correct inspect mechanism for bent and damaged
cause of leakage. Check condition of O-ring parts, and repair as necessary.
seals on starter and VG control splines if AGB
pad leakage is excessive.
4-12 Change 2
Figure 4-1. Hookup for Variable Stator Vane System Actuation (Early Configuration)
Change 2 4-13
(2) If binding was not cause of trou- b. System Operates but is Off Schedule.
ble, install a 0-100 psi (0-690 kPA) gage at oil System schedule should not shift during opera-
supply point to speed sensor, and a 0-500 psi tion. If system has not been tampered with,
(0-3450 kPa) gage in line from speed sensor to repeat checks specified in step a., but in the
servo valve. Start engine and operate at idle. following order: substep 4., substep 2., and
Oil supply pressure should be about same as substep 1. If these checks are negative, replace
engine oil pressure, and discharge pressure speed sensor.
should be 380 to 500 psig (2622-3450 kPa). If
inlet pressure is low, check oil filters for con- c. System Operates but is Erratic. Repeat
tamination. If discharge oil pressure is not checks specified in step a., with particular
within limits, replace speed sensor. attention to looking for binding feedback cable
and demand linkage, and damage to variable
(3) If problem still exists, operate stator mechanism. Output oil pressure should
engine and slowly increase its speed from idle be steady and not fluctuating more than
(5000 rpm). Observe output lever arm on 10 psig (69 kPa). If oil pressure is fluctuating
speed sensor to see if it moves. If it does not beyond limits, replace speed sensor.
move per appropriate schedule in work pack-
age WP 118 00 or SWP 118 01 replace speed 4-12.23 Gas Generator Speed Instrumen-
sensor. Output arm should move smoothly and tation Troubleshooting Procedure.
freely.
a. Disconnect electrical connector from
(4) If trouble still is not corrected, gas generator speed pickup sensor on acces-
shut down engine. Disconnect oil supply and sory gearbox.
return lines at servo valve. Connect regulated
dry nitrogen pressure source to supply port on b. Using an ohmmeter, measure the resis-
servo valve. Clean, dry shop air may be used in tance between pins A and B on the speed
place of dry nitrogen. Connect oil return line to pickup. Resistance limits are 200 ± 20 ohms.
oil tank or suitable container. Apply pressure If not within limits, replace pickup. If resis-
not to exceed 200 psig (138 kPa). Loosen rig tance is within limits, proceed to step c.
plate on speed sensor output arm to permit
engagement of arm against manual stop. Move c. Connect an ac voltmeter between pins
output lever arm of speed sensor from stop to A and B on the speed pickup connector.
stop, and observe action of servo valve. Actua-
tors should move linkage to full extend posi- d. Motor gas generator. At maximum
tion when speed sensor lever arm is moved to motoring speed, voltage should be 30-40 volts
maximum stop. Check demand linkage and peak-to-peak.
feedback cable to assure they are not discon-
nected or broken, and that they move freely. If e. If speed pickup voltage is within limits,
they operate correctly, replace servo valve. check continuity and insulation resistance of
speed pickup cables and connectors.
4-14 Change 2
g. If voltage is not within limits, check for (b) If accessory gearbox turns
proper gap setting on speed pickup. Refer to freely, inspect inlet gearbox. If inlet gearbox is
WP 108 00. If gap is out of limits, adjust and good, replace gas generator.
recheck voltage. If gap is within limits, replace
pickup. (c) If accessory gearbox did not
turn in step (a), remove gearbox driven acces-
4-12.24 Gearbox Troubleshooting sories one at a time and attempt to rotate trans-
Procedure. fer gearbox after each removal.
(2) If accessory gearbox does not turn (c) If bevel gear does not rotate,
proceed as follows: replace accessory gearbox. If bevel gear
rotates, remove and inspect radial drive shaft.
(a) Remove radial drive shaft
and attempt to rotate accessory gearbox. (d) If radial drive shaft is not
damaged, inspect inlet gearbox.
Change 2 4-15
a. Remove ignition exciter input leads g. If spark igniter(s) do not fire correctly,
and connect an ac voltmeter to one lead. Ener- replace igniter(s) and test per steps d, e, and f.
gize ignition system and check for 115 vac.
Repeat on other lead. Depending on the results h. If igniters still do not fire correctly,
of this test, proceed as indicated in the follow- check continuity and insulation resistance of
ing: ignition leads. Insulation resistance should be
25 megohms minimum. If lead(s) check satis-
(1) If input voltage is not correct, factorily, replace ignition exciter(s) and repeat
check supply voltage at interface connector. If steps d, e, and f.
voltage is correct, trouble is in cables. Trouble-
shoot cables (step h).
4-16 Change 2
Change 2 4-17
4-12.27 Power Turbine Inlet T5.4 Thermo- within the starter duty cycle. Refer to pack-
couple System Troubleshooting Procedure. ager’s manual.
4-18 Change 2
Change 2 4-19
NOTES:
(1) Average of 2 measurements. Reverse ohmmeter leads for second measurement.
(2) Jumper wire connected between pins A and B on forward connector; tester measure-
ments taken at aft connector. No. 16 female contacts required on jumper.
(3) Megger checks made at forward connector only with jumper wire removed.
(4) Connector shell.
(5) Install jumper between pins A and B of connector J5. Read A to B or C or D at connector
J1 or J2. Conductor resistance is 3.7 to 4.7 ohms. With jumper wire remaining between
pins A and B of connector J, read resistance at pins A to B or C or D at connector J3 or
J4. Conductor resistance is 4.2 to 5.4 ohms.
(6) Install jumper wire between pins A and B of connector J5. Read A to B or C or D at con-
nector J1 or J2. Conductor resistance is 2.3 to 3.0 ohms. With jumper wire remaining
between pins A and B of connector J5, read resistance at A to B or C or D at connector J3
or J4. Conductor resistance is 2.8 to 3.6 ohms.
(7) Circuit resistance shall meet the following requirements:
(a) The resistance of each KP circuit shall be between .81 to .90 ohm at
65 to 75°F (18.33 to 23.89°C).
(b) The resistance of each KN circuit shall be between .33 to .37 ohm at
65 to 75°F (18.33 to 23.89°C).
(c) With all terminal parts shorted, the loop resistance between the KN contact
(contact A) and any KP contact (contact B, C, or D) shall be between 1.11 to
1.27 ohms at 65 to 75°F (18.33 to 23.89°C).
(8) Insulation resistance of the cable assembly shall be measured between each individual
circuit and the protective outer brade or connector shell, and between individual circuits.
This measurement shall be made at 30 to 110°F (-1.11 to 43.33°C) and 500 Vdc, and the
cable shall be dry with an acceptance test limit of 10 megohm minimum.
(9) DC resistance at 60 to 80°F (15.56 to 26.67°C) to be as follows:
(a) Between points F (Figure 4-2A) and G .44 to .83 ohm.
4-20 Change 2
Figure 4-2. T5.4 Thermocouple System Schematic - P and G Series (Except GA101)
Change 2 4-21
4-22 Change 2
Change 2 4-23
4-12.27A Power Turbine Inlet T5.4 Thermo- 4-12.28 Adjustment of Engine High Pres-
couple System Temperature Spread Trou- sure (HP) Recoup Cavity Pressure (GE, PE,
bleshooting Procedure. PH, and PL Models).
4-24 Change 2
Figure 4-3. High Pressure Recoup Air Metering Spacer Configuration - Left Side
Pneumatic System (Sheet 1 of 3)
Change 2 4-25
Figure 4-3. High Pressure Recoup Air Metering Spacer Configuration - Left Side
Pneumatic System (Sheet 2 of 3)
4-26 Change 2
Figure 4-3. High Pressure Recoup Air Metering Spacer Configuration - Left Side
Pneumatic System (Sheet 3 of 3)
Change 2 4-27
4-28 Change 2
Change 2 4-29
4-30 Change 2
Figure 4-6. Preferred Operating Range for High Pressure Recoup (GE, PE, and PL Models)
(Sheet 1 of 2)
Change 2 4-31
Figure 4-6. Preferred Operating Range for High Pressure Recoup (GE, PE, and PL Models)
(Sheet 2 of 2)
4-32 Change 2
Figure 4-6. Preferred Operating Range for High Pressure Recoup (PH Models)
(Sheet 3 of 3)
Change 2 4-33
Ohmmeter Conductor
Nomenclature Connections Resistance Limits (1)
NOTES:
(1) Average of 2 measurements. Reverse ohmmeter leads for second measurement.
4-34 Change 2